Dodge - Durango 2wd - Workshop Manual - 2001 - 2001

Factory Workshop Manual Make Dodge Model Durango 2wd Engine and year V8-4.7L VIN N (2001) 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Alarm Module: Locations The SKIM is located on the right side of the steering column, below the ignition lock cylinder housing and is concealed beneath the steering column shrouds. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 7 Alarm Module: Diagrams Sentry Key Immobilizer Module Sentry Key Immobilizer Module Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 8 Alarm Module: Description and Operation Fig.10 Sentry Key Immobilizer Module SENTRY KEY IMMOBILIZER MODULE The Sentry Key Immobilizer Module (SKIM) is the primary component of the Sentry Key Immobilizer System (SKIS). The SKIM is located on the right side of the steering column, below the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKIM has an integral molded plastic halo-like antenna ring that extends from one end. When the SKIM is properly installed on the steering column, the antenna ring is oriented around the circumference of the ignition lock cylinder housing. A single integral connector receptacle containing six terminal pins is located on the opposite end of the SKIM housing from the antenna ring. A stamped metal mounting bracket secured to the SKIM housing has a U-shaped clip formation that is used to secure the unit to the right lower flange of the steering column jacket. The SKIM cannot be adjusted or repaired. If faulty or damaged, the entire SKIM unit must be replaced. The Sentry Key Immobilizer Module (SKIM) contains a Radio Frequency (RF) transceiver and a microprocessor. The SKIM transmits RF signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring integral to the SKIM housing. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKIM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKIM also communicates over the Programmable Communications Interface (PCI) data bus with the Powertrain Control Module (PCM), the Electro Mechanical Instrument Cluster (EMIC) and/or the DRB III scan tool. The SKIM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKIM. For added system security, each SKIM is programmed with a unique Secret Key code. This code is stored in memory, sent over the PCI data bus to the PCM, and is encoded to the transponder of every Sentry Key that is programmed into the SKIM. Therefore, the Secret Key code is a common element that is found in every component of the Sentry Key Immobilizer System (SKIS). Another security code, called a PIN, is used to gain access to the SKIM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKIM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a PCI data bus message from the PCM during SKIS initialization. In the event that a SKIM replacement is required, the Secret Key code can be transferred to the new SKIM from the PCM using the DRB III® scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKIM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKIM replacement will also require new Sentry Keys. The DRB III scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the ON position, the SKIM transmits an RF signal to the transponder in the ignition key. The SKIM then waits for an RF signal response from the transponder. If the response received identifies the key as valid, the SKIM sends a valid key message to the PCM over the PCI data bus. If the response received identifies the key as invalid, or if no response is received from the key transponder, the SKIM sends an invalid key message to the PCM. The PCM will enable or disable engine operation based upon the status of the SKIM messages. It is important to note that the default condition in the PCM is an invalid key; therefore, if no message is received from the SKIM by the PCM, the engine will be disabled and the vehicle immobilized after two seconds of running. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 9 The SKIM also sends SKIS indicator status messages to the EMIC over the PCI data bus to tell the EMIC how to operate the SKIS indicator. This indicator status message tells the EMIC to turn the indicator ON for about three seconds each time the ignition switch is turned to the ON position as a bulb test. After completion of the bulb test, the SKIM sends indicator status messages to the EMIC to turn the indicator off, turn the indicator ON, or to flash the indicator ON and OFF. If the SKIS indicator flashes or stays ON solid after the bulb test, it signifies a SKIS fault. If the SKIM detects a system malfunction and/or the SKIS has become inoperative, the SKIS indicator will stay ON solid. If the SKIM detects an invalid key or if a key transponder-related fault exists, the SKIS indicator will flash. If the vehicle is equipped with the Customer Learn transponder programming feature, the SKIM will also send messages to the EMIC to flash the SKIS indicator and to generate a single audible chime tone whenever the Customer Learn programming mode is being utilized. (Refer to VEHICLE THEFT SECURITY - STANDARD PROCEDURE - SENTRY KEY TRANSPONDER PROGRAMMING). The SKIS performs a self-test each time the ignition switch is turned to the ON position, and will store fault information in the form of Diagnostic Trouble Codes (DTC's) in SKIM memory if a system malfunction is detected. The SKIM can be diagnosed, and any stored DTC's can be retrieved using a DRB III scan tool. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 10 Alarm Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the steering column opening cover from the instrument panel. 3. If the vehicle is so equipped, grasp the tilt steering column knob firmly and pull it straight rearward to remove it from the tilt steering column adjuster mechanism lever located on the left side of the column just below the multi-function switch control stalk. 4. From below the steering column, remove the two outboard screws that secure the upper shroud to the lower shroud. 5. Push gently inward on both sides of the upper shroud near the parting line between the upper and lower shrouds to release the snap features that secure it to the lower shroud. 6. Remove the upper shroud from the lower shroud. 7. From below the steering column, remove the one center screw that secures the lower shroud to the steering column lock housing. 8. Remove the lower shroud from the steering column. Fig.10 Sentry Key Immobilizer Module 9. Disconnect the instrument panel wire harness connector for the Sentry Key Immobilizer Module (SKIM) from the SKIM connector receptacle. 10. Remove the screw that secures the SKIM to the steering column lock housing. 11. Disengage the SKIM antenna ring from around the ignition lock cylinder housing. INSTALLATION 1. Position the Sentry Key Immobilizer Module (SKIM) onto the steering column with the antenna ring oriented around the ignition lock cylinder housing. 2. Install and tighten the screw that secures the SKIM to the steering column lock housing. Tighten the screw to 2 Nm (20 in. lbs.). 3. Reconnect the instrument panel wire harness connector for the SKIM to the SKIM connector receptacle. 4. Position the lower shroud onto the steering column. 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column lock housing. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud onto the steering column. If the vehicle is equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the openings in the right side of the upper and lower shrouds. 7. Align the snap features on the upper shroud with the receptacles on the lower shroud and apply hand pressure to snap them together. 8. From below the steering column, install and tighten the two screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). 9. If the vehicle is so equipped, align the tilt steering column knob with the tilt steering column adjuster mechanism lever located on the left side of the column just below the multi-function switch control stalk and using hand pressure push the knob firmly onto the lever. 10. Reinstall the steering column opening cover onto the instrument panel. 11. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams Door Module: Diagrams Driver Door Module C1 Driver Door Module C2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Description and Operation Power Door Lock Control Module: Description and Operation DRIVER DOOR MODULE A Driver Door Module (DDM) is used on all models equipped with power locks, power windows, and power mirrors. The driver door module consists of a molded plastic housing that is secured with three screws to a molded plastic switch bezel. The switch bezel is secured by metal snap clips within an opening near the forward end of the arm rest in the driver side front door trim panel so that the DDM can be serviced without removing the front door trim panel. Two integral connector receptacles on the back of the DDM connect it to the vehicle electrical system through two take outs and connectors of the left front door wire harness. The DDM houses the following switches: Power Lock Switch - The DDM includes a two-way, momentary, resistor multiplexed switch to control the power lock system. - Power Mirror Selector Switch - A three-position rocker switch in the DDM selects the right or left power mirror for adjustment, or turns the power mirror system OFF. - Power Mirror Adjustment Switches - Four momentary, arrowhead shaped, directional switches allow the driver to adjust the selected power mirror in the Up, Down, Right, or Left directions. - Power Window Lockout Switch - A two-way, latching, push-button switch in the DDM allows the vehicle operator to lock out the power window switches on each passenger door so that the passenger door power windows may be operated only from the master switches in the DDM. - Power Window Switches - The DDM houses a two-way, momentary power window switch for the driver side front door. This switch also has a second detent in the Down direction and internal circuitry to provide an Auto-Down feature for the driver side front door power window. In addition to the power window switch for its own door, the DDM houses individual master switches for each passenger door power window. The DDM also incorporates several green Light Emitting Diodes (LEDs) that illuminate the power lock and power window switch paddles, and the power mirror switch directional buttons to improve switch visibility in dark ambient lighting conditions. The DDM cannot be adjusted or repaired and, if faulty or damaged, the entire DDM unit must be replaced. The Driver Door Module (DDM) combines a power lock switch, a driver power window switch with an Auto-down feature, master switches for each passenger door power window, a power window lockout switch, a power mirror selector switch, and four power mirror adjustment switches in a single unit. The switches in the DDM can be diagnosed using conventional diagnostic tools and methods. Power Lock Switch The DDM power lock switch circuitry is connected in series between ground and the driver door switch mux input of the Central Timer Module ( CTM). Each power lock switch position (Lock, Unlock, and Neutral) provides a different resistance value to the CTM input, which allows the CTM to sense the switch position. Based upon the power lock switch input, the CTM controls the battery and ground feed outputs to the individual power lock motors to lock or unlock the door and liftgate latches. The Light-Emitting Diode (LED) in the DDM power lock switch is connected to battery current through the power window circuit breaker in the Junction Block (JB) on a fused ignition switch output (run-acc) circuit so that the switch will be illuminated whenever the ignition switch is in the ON or Accessory positions. Power Window Switches The DDM power window switch circuitry is connected to battery current through a circuit breaker in the Junction Block (JB) on a fused ignition switch output (run-acc) circuit so that the power windows will operate whenever the ignition switch is in the ON or Accessory positions. Each two-way, momentary master passenger power window switch in the DDM provides battery current and ground to the individual power window switches on each passenger door so that the power window switch controls the battery current and ground feeds to its respective power window motor. The DDM switch for the driver side front door power window is labeled with the text "Auto" and includes an auto-down feature. When this switch is depressed to a second momentary detent position and released, the driver door power window is automatically operated through an internal circuit and relay to its fully lowered position. The Auto-down event is cancelled if the switch paddle is depressed a second time in either the Up or Down direction. When the two position window lockout switch in the DDM is depressed and latched in the lockout position, the battery current feed to each of the individual passenger power window switches is interrupted so that the passenger door power windows can only be operated from the master switches in the DDM. The window lockout switch also controls the battery current feed for the LED in each passenger power window switch so that the switch will not be illuminated when it is locked out. Power Mirror Switches The DDM power mirror switch circuitry is connected to battery current through a fuse in the JB on a fused B(+) circuit so that the power mirrors remain operational regardless of the ignition switch position. A rocker type selector switch has three positions, one to select the right mirror, one to select the left mirror, and a neutral OFF position. After the right or left mirror is selected, one of four directional buttons is depressed to move the selected mirror Up, Down, Right or Left. The DDM power mirror switch circuitry controls the battery current and ground feeds to each of the four (two in each mirror head) power mirror motors. The Light-Emitting Diode (LED) in the DDM power mirror switch is connected to battery current through the power window circuit breaker in the Junction Block (JB) on a fused ignition switch output (run-acc) circuit so that the switch directional buttons will be illuminated whenever the ignition switch is in the ON or Accessory positions. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Description and Operation > Page 18 Power Door Lock Control Module: Testing and Inspection The Light-Emitting Diode (LED) illumination lamps for all of the Driver Door Module (DDM) power window, power lock, and power mirror switches receive battery current through the power window circuit breaker in the Junction Block (JB). If all of the LEDs are inoperative in the DDM, be certain to diagnose the power window system before replacing the switch unit. (Refer to POWER WINDOWS - DIAGNOSIS AND TESTING). If only one LED in the DDM is inoperative, replace the faulty DDM. If the driver side front door power window operates in a normal manner, but the Auto-Down feature is inoperative, replace the faulty DDM. 1. Disconnect and isolate the battery negative cable. Remove the DDM from the door trim panel. Disconnect the door wire harness connectors for the DDM from the DDM connector receptacles. Driver Door Module Switch Tests (Part 1 Of 2) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Description and Operation > Page 19 Driver Door Module Switch Tests (Part 2 Of 2) Fig.2 Driver Door Module Connector C1 Receptacle Fig. 3 Driver Door Module Connector C2 Receptacle 2. Test the DDM switch continuity. See the Driver Door Module Switch Tests chart to determine if the continuity is correct for the suspect switches in each switch position and/or. If not OK, replace the faulty DDM as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Description and Operation > Page 20 Power Door Lock Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Fig. 4 Driver Door Module 2. Using a trim stick or another suitable wide flat bladed tool and starting at the rear of the Driver Door Module (DDM) bezel, gently pry the DDM up and out from the driver side front door trim panel. 3. Pull the DDM away from the trim panel opening far enough to access the two connector receptacles on the back of the unit. 4. Disconnect the two door wire harness connectors for the DDM from the DDM connector receptacles. 5. Remove the DDM from the door trim panel. INSTALLATION 1. Position the Driver Door Module (DDM) to the opening in the driver side front door trim panel. 2. Reconnect the two door wire harness connectors for the DDM to the DDM connector receptacles. 3. Insert the front of the DDM bezel into the opening in the driver side front door trim panel. 4. Using hand pressure, gently and evenly press down on the rear of the DDM bezel until it snaps into place. 5. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations Seat Heater Control Module: Locations Fig. 8 Heated Seat Module - Typical The heated seat module is located under the heated seat switches, where it is secured to a mounting bracket that is also part of the center console. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 24 Heated Seat Module Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 25 Seat Heater Control Module: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 26 Seat Heater Control Module: Description and Operation Fig. 8 Heated Seat Module - Typical HEATED SEAT MODULE Vehicles equipped with heated seats utilize a heated seat module. The heated seat module is located under the heated seat switches, where it is secured to a mounting bracket that is also part of the center console. The heated seat module has a single connector receptacle that allows the module to be connected to all of the required inputs and outputs through the center console wire harness. The heated seat module is an electronic microprocessor controlled device designed and programmed to use inputs from the ignition switch, the two heated seat switches and the two heated seat sensors to operate and control the heated seat elements in both front seats and the two heated seat indicator lamp Light-Emitting Diodes (LEDs) in each heated seat switch. The heated seat module is also programmed to perform self-diagnosis of certain heated seat system functions and provide feedback of that diagnosis through the heated seat switch indicator lamps. The heated seat module cannot be repaired. If the heated seat module is damaged or faulty, the entire module must be replaced. The heated seat module operates on fused battery current received from the ignition switch. The module is grounded at all times through a ground screw located on the drivers B-pillar. Inputs to the module include a resistor multiplexed heated seat switch request circuit for each of the two heated seat switches and the heated seat sensor inputs from the seat cushions of each front seat. In response to those inputs the heated seat module controls battery current feeds to the heated seat elements and sensors, and controls the ground for the heated seat switch indicator lamps. When a heated seat switch (Driver or Passenger) request signal is received by the heated seat module, the module energizes the proper indicator lamp (Low or High) in the switch by grounding the indicator lamp circuit to indicate that the heated seat system is operating. At the same time, the heated seat module energizes the selected heated seat sensor circuit and the sensor provides the module with an input indicating the surface temperature of the selected seat cushion. The Low heat set point is about 35 °C (100.4 °F), and the High heat set point is about 42 °C (107.6 °F). If the seat cushion surface temperature input is below the temperature set point for the selected temperature setting, the heated seat module energizes an N-channel Field Effect Transistor (N-FET) within the module which energizes the heated seat elements in the selected seat cushion and back. When the sensor input to the module indicates the correct temperature set point has been achieved, the module de-energizes the N-FET which de-energizes the heated seat elements. The heated seat module will continue to cycle the N-FET as needed to maintain the selected temperature set point. If the heated seat module detects a heated seat sensor value input that is out of range or a shorted or open heated seat element circuit, it will notify the vehicle operator or the repair technician of this condition by flashing the High and/or Low indicator lamps in the affected heated seat switch. Refer to Heated Seat System and Heated Seat Module in Electronic Control Modules for the location of the proper heated seat module diagnosis and testing procedures. Also refer to the Body Diagnostic for additional diagnosis and testing procedures. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 27 Seat Heater Control Module: Testing and Inspection Refer to Wiring Diagrams in for the location of complete heated seat system wiring diagrams. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. If a heated seat fails to heat and one or both of the indicator lamps on a heated seat switch flash, refer to Heated Seat System in the Electrical for the location of the proper heated seat system diagnosis and testing procedures. If a heated seat heats but one or both indicator lamps on the heated seat switch fail to operate, test the heated seat switch. Refer to Heated Seat Switch in the heated seat for the location of the proper heated seat switch diagnosis and testing procedures. If the heated seat switch checks OK, go to Step 4. If both seats (driver and passenger) fail to heat and the indicator lamps on the heated seat switches for both seats fail to operate, test the ignition switch output circuit. If OK, go to Step 2 If not OK, repair the battery feed circuits to the heated seat switches. If only one seat (driver or passenger) fails to heat and the indicator lamps on the heated seat switch for that seat fail to operate, test that heated seat switch. Refer to Heated Seat Switch in the heated seat for the location of the proper heated seat switch diagnosis and testing procedures. If the heated seat switch checks OK, go to Step 3. If a heated seat switch indicator lamp remains illuminated after the heated seat has been turned OFF, go to Step 5. 2. Disconnect and isolate the battery negative cable. Disconnect the wire harness connector for the heated seat module from the heated seat module connector receptacle. Check for continuity between the ground circuit cavity of the wire harness connector for the heated seat module and a good ground. If not OK, repair the open ground circuit to ground as required. If OK, reconnect the battery negative cable. Turn the ignition switch to RUN position and check for battery voltage at the heated seat module connector receptacle. If OK, go to (3). If not OK, repair battery feed circuit to the heated seat module connector receptacle. 3. Turn the ignition switch to the OFF position. Disconnect the wire harness connector for the heated seat module from the heated seat module connector receptacle. Remove the heated seat switches from the center console. Disconnect the wire harness connector(s) from the connector receptacle(s) of the inoperative heated seat switch(es). Check for continuity between the inoperative driver and/or passenger heated seat switch circuit cavities of the heated seat switch wire harness connector(s) and the heated seat module wire harness connector. There should be continuity. If OK, replace the faulty heated seat module. If not OK, repair the open driver and/or passenger heated seat switch circuit as required. 4. Disconnect and isolate the battery negative cable. Disconnect the wire harness connector for the heated seat module from the heated seat module connector receptacle. Remove the heated seat switches from the center console. Check for continuity between the inoperative left and/or right seat high and/or low heat LED driver circuit cavities of the heated seat switch wire harness connector(s) and the heated seat module wire harness connector. There should be continuity. If OK, replace the faulty heated seat module. If not OK, repair the open left or right seat high or low heat LED driver circuit as required. 5. Disconnect and isolate the battery negative cable. Disconnect the wire harness connector for the heated seat module from the heated seat module connector receptacle. Remove the heated seat switches from the center console. Disconnect the center console wire harness connector(s) from the connector receptacle(s) of the heated seat switch(es) with the inaccurate indicator lamp(s). Check for continuity between the inoperative left and/or right seat high and/or low heat LED driver circuit cavity of the heated seat switch wire harness connector(s) and a good ground. There should be no continuity. If OK, replace the faulty heated seat module. If not OK, repair the shorted left or right seat high or low heat LED driver circuit as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 28 Seat Heater Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the seat heater switches from the center console. Refer to the procedure in the Heated Seat. 3. Open the center console and remove the center console insert and floor mat, if equipped. 4. Using a long flat bladed screwdriver, insert the screwdriver through the heated switch mounting holes in the center console and depress the heated seat module mounting bracket retaining tabs. With the retaining tabs depressed reach into the center console and tilt the front wall of the console rearward. The heated seat module is now visible. 5. Remove the heated seat module from the mounting bracket by removing the retaining screws. 6. Disconnect the center console wire harness connector from the connector receptacle on the back of the heated seat module. 7. Remove the heated seat module from the vehicle. INSTALLATION 1. Position the heated seat module in the center console. 2. Connect the center console wire harness connector on the connector receptacle on the back of the heated seat module. 3. Install the heated seat module retaining screws. 4. Rotate the front center console wall up into position and install the center console insert and floor mat, if equipped. 5. Install the seat heater switches in the center console. Refer to the procedure in the heated seat. 6. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Controller Antilock Brake: > 08-035-00 > Nov > 00 > Brakes - Vehicle Surge While Speed Control is Engaged Controller Antilock Brake: Customer Interest Brakes - Vehicle Surge While Speed Control is Engaged NUMBER: 08-035-00 GROUP: Electrical DATE: Nov. 10, 2000 SUBJECT: Vehicle Surge While Speed Control Is Engaged OVERVIEW: This bulletin involves installing a new antilock brake control module. MODELS: 2001 (AN) Dakota 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH SPEED CONTROL (SALES CODE NHM) AND FOUR WHEEL ANTILOCK BRAKES (SALES CODE BGK) BUILT ON OR BEFORE THE ILLUSTRATED DATES: SYMPTOM/CONDITION: The vehicle surges while the speed control is engaged at 74 - 76 km/h (46 - 47 mph) and/or at 109 - 111 km/h (68 - 69 mph). DIAGNOSIS/REPAIR PROCEDURES: Road test the vehicle in a location where vehicle speeds of 74 - 76 km/h (46-47 mph) and/or 109 111 km/h (68 - 69 mph) can be maintained safely. Set the speed control at 74 - 76 km/h (46 - 47 mph) or at 109 - 111 km/h (68 - 69 mph). If the vehicle surges, disengage the speed control. If the vehicle still surges, further diagnosis is required. If the vehicle surges only while the speed control is engaged, perform the Repair Procedure. NOTE: DUE TO THE NATURE OF THIS CONDITION, IT MAY BE DIFFICULT TO DUPLICATE THE SYMPTOM. IF THE CUSTOMER INDICATES THAT THE VEHICLE SURGES AT 74 - 76 KM/H (46 - 47 MPH) AND/OR AT 109 - 111 KM/H (68 - 69 MPH) ONLY WHEN THE SPEED CONTROL IS ENGAGED, PERFORM THE REPAIR PROCEDURE. PARTS REQUIRED: NOTE: ANTILOCK BRAKE CONTROLLER AVAILABILITY IS RESTRICTED. THE STAR CENTER MUST BE CONTACTED TO GET AUTHORIZATION AND TO ORDER A CONTROLLER. THE STAR CENTER'S PHONE NUMBER IS 1-800-850-STAR (7827). WHEN THE AUTOMATED ANSWERING SYSTEM REQUESTS A GROUP SELECTION, SELECT BRAKES AND THEN SELECT THE KELSEY HAYES GROUP Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Controller Antilock Brake: > 08-035-00 > Nov > 00 > Brakes - Vehicle Surge While Speed Control is Engaged > Page 38 EQUIPMENT REQUIRED: REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. NOTE: ONCE THE ANTILOCK BRAKE CONTROL MODULE (CAB) IS REPLACED, THE REAR AXLE TYPE AND TIRE SIZE MUST BE PROGRAMED INTO THE NEW CAB. 1. Disconnect battery negative cable. 2. Push the harness connector locks to release the locks, (Fig. 1) then remove the connectors from the CAB. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Controller Antilock Brake: > 08-035-00 > Nov > 00 > Brakes - Vehicle Surge While Speed Control is Engaged > Page 39 3. Disconnect the pump motor connector (Fig. 2). 4. Remove screws attaching CAB to the Hydraulic control Unit (HCU) (Fig. 3). 5. Remove the CAB. 6. Place the new CAB onto the HCU (see Parts Required section). NOTE: ENSURE THE CAB SEAL IS IN POSITION BEFORE INSTALLATION. 7. Install the mounting screws and tighten to 4-4.7 N.m (36-42 in. lbs.). 8. Connect the pump motor harness. 9. Connect the harnesses to the CAB and lock the connectors. 10. Connect battery. NOTE: THE NEW CAB MUST HAVE THE TIRE SIZE AND AXLE TYPE PROGRAMMED INTO THE NEW CONTROLLER IN ORDER TO HAVE THE CONTROLLER COMMUNICATE THE PROPER VEHICLE SPEED. FAILURE TO PROPERLY PROGRAM THE REPLACEMENT CAB WILL RESULT IN A BLINKING ABS INDICATOR. 11. Inspect rear tires to determine tire sizes. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Controller Antilock Brake: > 08-035-00 > Nov > 00 > Brakes - Vehicle Surge While Speed Control is Engaged > Page 40 12. Determine which rear axle type is used on this vehicle. Refer to the following graphics to help in identifying axle types (Fig. 4) (Fig. 5). 13. Using the DRBIII(R) select: MISC in the Antilock Brake menu. Then, SET PINION FACTOR. NOTE: THE DRBIII(R) MENU SCREEN CAN ONLY PROGRAM PRODUCTION SIZE TIRES THAT WERE CERTIFIED FOR THE VEHICLE WHEN THE VEHICLE WAS MANUFACTURED. IF THE TIRES ON THE VEHICLE DO NOT MATCH TIRE SIZES AVAILABLE ON THE DRBIII(R) MENU SCREEN, THEN THE TIRE ON THE VEHICLE WAS NEVER CERTIFIED FOR USAGE. 14. Turn the ignition switch to the RUN position (engine not running). 15. With the DRBIII(R), program the correct tire size and rear axle type. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Controller Antilock Brake: > 08-035-00 > Nov > 00 > Brakes - Vehicle Surge While Speed Control is Engaged > Page 41 16. Road test the vehicle above 48 km/h (30 mph) for at least two minutes to ensure that the antilock brake system functions as designed. If the ABS warning lamp illuminates during the road test, further diagnosis is required. Refer to the appropriate Chassis Diagnostic Manual or the service information available in the MDS2. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Controller Antilock Brake: > 08-035-00 > Nov > 00 > Brakes - Vehicle Surge While Speed Control is Engaged Controller Antilock Brake: All Technical Service Bulletins Brakes - Vehicle Surge While Speed Control is Engaged NUMBER: 08-035-00 GROUP: Electrical DATE: Nov. 10, 2000 SUBJECT: Vehicle Surge While Speed Control Is Engaged OVERVIEW: This bulletin involves installing a new antilock brake control module. MODELS: 2001 (AN) Dakota 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH SPEED CONTROL (SALES CODE NHM) AND FOUR WHEEL ANTILOCK BRAKES (SALES CODE BGK) BUILT ON OR BEFORE THE ILLUSTRATED DATES: SYMPTOM/CONDITION: The vehicle surges while the speed control is engaged at 74 - 76 km/h (46 - 47 mph) and/or at 109 - 111 km/h (68 - 69 mph). DIAGNOSIS/REPAIR PROCEDURES: Road test the vehicle in a location where vehicle speeds of 74 - 76 km/h (46-47 mph) and/or 109 111 km/h (68 - 69 mph) can be maintained safely. Set the speed control at 74 - 76 km/h (46 - 47 mph) or at 109 - 111 km/h (68 - 69 mph). If the vehicle surges, disengage the speed control. If the vehicle still surges, further diagnosis is required. If the vehicle surges only while the speed control is engaged, perform the Repair Procedure. NOTE: DUE TO THE NATURE OF THIS CONDITION, IT MAY BE DIFFICULT TO DUPLICATE THE SYMPTOM. IF THE CUSTOMER INDICATES THAT THE VEHICLE SURGES AT 74 - 76 KM/H (46 - 47 MPH) AND/OR AT 109 - 111 KM/H (68 - 69 MPH) ONLY WHEN THE SPEED CONTROL IS ENGAGED, PERFORM THE REPAIR PROCEDURE. PARTS REQUIRED: NOTE: ANTILOCK BRAKE CONTROLLER AVAILABILITY IS RESTRICTED. THE STAR CENTER MUST BE CONTACTED TO GET AUTHORIZATION AND TO ORDER A CONTROLLER. THE STAR CENTER'S PHONE NUMBER IS 1-800-850-STAR (7827). WHEN THE AUTOMATED ANSWERING SYSTEM REQUESTS A GROUP SELECTION, SELECT BRAKES AND THEN SELECT THE KELSEY HAYES GROUP Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Controller Antilock Brake: > 08-035-00 > Nov > 00 > Brakes - Vehicle Surge While Speed Control is Engaged > Page 47 EQUIPMENT REQUIRED: REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. NOTE: ONCE THE ANTILOCK BRAKE CONTROL MODULE (CAB) IS REPLACED, THE REAR AXLE TYPE AND TIRE SIZE MUST BE PROGRAMED INTO THE NEW CAB. 1. Disconnect battery negative cable. 2. Push the harness connector locks to release the locks, (Fig. 1) then remove the connectors from the CAB. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Controller Antilock Brake: > 08-035-00 > Nov > 00 > Brakes - Vehicle Surge While Speed Control is Engaged > Page 48 3. Disconnect the pump motor connector (Fig. 2). 4. Remove screws attaching CAB to the Hydraulic control Unit (HCU) (Fig. 3). 5. Remove the CAB. 6. Place the new CAB onto the HCU (see Parts Required section). NOTE: ENSURE THE CAB SEAL IS IN POSITION BEFORE INSTALLATION. 7. Install the mounting screws and tighten to 4-4.7 N.m (36-42 in. lbs.). 8. Connect the pump motor harness. 9. Connect the harnesses to the CAB and lock the connectors. 10. Connect battery. NOTE: THE NEW CAB MUST HAVE THE TIRE SIZE AND AXLE TYPE PROGRAMMED INTO THE NEW CONTROLLER IN ORDER TO HAVE THE CONTROLLER COMMUNICATE THE PROPER VEHICLE SPEED. FAILURE TO PROPERLY PROGRAM THE REPLACEMENT CAB WILL RESULT IN A BLINKING ABS INDICATOR. 11. Inspect rear tires to determine tire sizes. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Controller Antilock Brake: > 08-035-00 > Nov > 00 > Brakes - Vehicle Surge While Speed Control is Engaged > Page 49 12. Determine which rear axle type is used on this vehicle. Refer to the following graphics to help in identifying axle types (Fig. 4) (Fig. 5). 13. Using the DRBIII(R) select: MISC in the Antilock Brake menu. Then, SET PINION FACTOR. NOTE: THE DRBIII(R) MENU SCREEN CAN ONLY PROGRAM PRODUCTION SIZE TIRES THAT WERE CERTIFIED FOR THE VEHICLE WHEN THE VEHICLE WAS MANUFACTURED. IF THE TIRES ON THE VEHICLE DO NOT MATCH TIRE SIZES AVAILABLE ON THE DRBIII(R) MENU SCREEN, THEN THE TIRE ON THE VEHICLE WAS NEVER CERTIFIED FOR USAGE. 14. Turn the ignition switch to the RUN position (engine not running). 15. With the DRBIII(R), program the correct tire size and rear axle type. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Controller Antilock Brake: > 08-035-00 > Nov > 00 > Brakes - Vehicle Surge While Speed Control is Engaged > Page 50 16. Road test the vehicle above 48 km/h (30 mph) for at least two minutes to ensure that the antilock brake system functions as designed. If the ABS warning lamp illuminates during the road test, further diagnosis is required. Refer to the appropriate Chassis Diagnostic Manual or the service information available in the MDS2. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Page 51 Controller Antilock Brake: Specifications Controller Mounting Screws 53 in.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > EBC 325 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > EBC 325 > Page 54 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > Page 55 Controller Antilock Brake: Diagrams Controller Antilock Brake C1 Controller Antilock Brake C2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > Page 56 Controller Antilock Brake: Description and Operation CONTROLLER REAR WHEEL ANTILOCK BRAKES Fig. 3 RWAL Cab The Controller Antilock Brakes (CAB) is a microprocessor which handles testing, monitoring and controlling the ABS brake system operation. The CAB functions are: Perform self-test diagnostics. - Monitor the RWAL brake system for proper operation. - Control the RWAL valve solenoids. Fig. 4 CAB/HCU The CAB is mounted on the top of the hydraulic control unit. The CAB operates the ABS system and is separate from other vehicle electrical circuits. CAB voltage source is through the ignition switch in the RUN position. NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. For axle type refer to Differential and Driveline. System Self-test When the ignition switch is turned-ON the microprocessor RAM and ROM are tested. If an error occurs during the test, a DTC will be set into the RAM memory. However it is possible the DTC will not be stored in memory if the error has occurred in the RAM module were the DTC's are Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > Page 57 stored. Also it is possible a DTC may not be stored if the error has occurred in the ROM which signals the RAM to store the DTC. The CAB contains a self check program that illuminates the ABS warning light when a system fault is detected. Faults are stored in a diagnostic program memory and are accessible with the DRB scan tool. ABS faults remain in memory until cleared, or until after the vehicle is started approximately 50 times. Stored faults are not erased if the battery is disconnected. CAB Inputs The CAB continuously monitors the speed of the differential ring gear by monitoring signals generated by the rear wheel speed sensor. The CAB determines a wheel locking tendency when it recognizes the ring gear is decelerating too rapidly. The CAB monitors the following inputs to determine when a wheel locking tendency may exists: Rear Wheel Speed Sensor - Brake Lamp Switch - Brake Warning Lamp Switch - Reset Switch - 4WD Switch (If equipped) CAB Outputs The CAB controls the following outputs for antilock braking and brake warning information: RWAL Valve - ABS Warning Lamp - Brake Warning Lamp Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > Page 58 Controller Antilock Brake: Service and Repair REMOVAL NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. For axle type refer to Differential and Driveline. Fig. 5 Harness Connector Locks 1. Push the CAB harness connector lock to release the lock and remove the connector from the controller. Fig. 6 Pump Motor Connector 2. Remove the RWAL valve harness and the pump motor connectors from the controller. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > Page 59 Fig. 7 RWAL Controller 3. Remove the controller mounting screws and remove the controller from the mounting bracket. INSTALLATION NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. 1. Position the controller on the bracket. 2. Install the mounting screws and tighten to 6 Nm (53 in. lbs). 3. Install the RWAL valve harness connector into the controller. 4. Install the CAB harness connector into the controller and push down on the connector lock. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Power Distribution Center Radiator Fan Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 64 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 65 Radiator Cooling Fan Motor Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 66 Radiator Fan Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 67 Radiator Cooling Fan Motor Relay: Description and Operation DESCRIPTION The radiator cooling fan relay is a 5-pin, solenoid type, mini-relay. It is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. OPERATION The electric radiator cooling fan is controlled by the Powertrain Control Module (PCM) through the radiator cooling fan relay. The PCM will activate the relay after receiving inputs from the engine coolant temperature sensor and/or an air conditioning on/off signal. Not Equipped With A/C: The relay is energized when coolant temperature is above approximately 103°C (217°F). It will then de-energize when coolant temperature drops to approximately 98°C (208°F). Equipped With A/C: In addition to using coolant temperatures to control cooling fan operation, the cooling fan will also be engaged when the air conditioning system has been activated. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations Power Distribution Center Blower Motor Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 72 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 73 Blower Motor Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 74 Rear Blower Motor Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Power Distribution Center A/C Clutch Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 78 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 79 Compressor Clutch Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 80 A/C Compressor Clutch Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 81 Compressor Clutch Relay: Description and Operation COMPRESSOR CLUTCH RELAY - FRONT The compressor clutch relay is an International Standards Organization (ISO) micro-relay. The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (footprint) is different, the current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The compressor clutch relay is an electromechanical device that switches battery current to the compressor clutch coil when the Powertrain Control Module (PCM) grounds the coil side of the relay. The PCM responds to inputs from the heater-A/C mode control switch, the evaporator temperature sensor, the loss of charge switch, and the pressure transducer. See Compressor Clutch Relay in the Diagnosis and Testing for more information. The compressor clutch relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identification and location. The compressor clutch relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 82 Compressor Clutch Relay: Testing and Inspection Fig.12 Compressor Clutch Relay RELAY TEST The compressor clutch relay is located in the Power Distribution Center (PDC). Refer to the PDC label for relay identification and location. Remove the relay from the PDC to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see the Relay Circuit Test below. If not OK, replace the faulty relay. RELAY CIRCUIT TEST 1. The relay common feed terminal cavity (30) is connected to fused battery feed. There should be battery voltage at the cavity for relay terminal 30 at all times. If OK, go to Step 2. If not OK, repair the open circuit to the fuse in the PDC as required. 2. The relay normally closed terminal (87A) is not used in this application. Go to Step 3. 3. The relay normally open terminal cavity (87) is connected to the compressor clutch coil. There should be continuity between this cavity and the A/C compressor clutch relay output circuit cavity of the compressor clutch coil wire harness connector. If OK, go to Step 4. If not OK, repair the open circuit as required. 4. The relay coil battery terminal (86) is connected to the fused ignition switch output (run/start) circuit. There should be battery voltage at the cavity for relay terminal 86 with the ignition switch in the ON position. If OK, go to Step 5. If not OK, repair the open circuit to the fuse in the junction block as required. 5. The coil ground terminal cavity (85) is switched to ground through the Powertrain Control Module (PCM). There should be continuity between this cavity and the A/C compressor clutch relay control circuit cavity of the PCM wire harness connector C (gray) at all times. If not OK, repair the open circuit as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 83 Compressor Clutch Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Fig. 13 Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for compressor clutch relay identification and location. 4. Unplug the compressor clutch relay from the PDC. INSTALLATION 1. Install the compressor clutch relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 2. Install the PDC cover. 3. Connect the battery negative cable. 4. Test the relay operation. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Locations Audible Warning Device Control Module: Locations The Central Timer Module is located behind the left side kick panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device Control Module: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 90 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 91 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 92 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 93 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 94 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 95 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 96 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 97 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 98 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 99 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 100 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 101 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 102 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 103 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 104 Audible Warning Device Control Module: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 105 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 106 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 107 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 108 Audible Warning Device Control Module: Connector Views Central Timer Module C1 Central Timer Module C2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 109 Central Timer Module C3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 110 Audible Warning Device Control Module: Electrical Diagrams 8w-45-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 111 8w-45-3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 112 8w-45-4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 113 8w-45-5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 114 8w-45-6 (Base) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 115 8w-45-7 (Light Package) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 116 8w-45-8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 117 8w-45-9 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 118 8w-45-10 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 119 8w-45-11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 120 8w-45-12 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 121 8w-45-13 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 122 8w-45-14 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 123 8w-45-15 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams See: Diagrams/Electrical Diagrams Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 124 Audible Warning Device Control Module: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 125 Audible Warning Device Control Module: Description and Operation For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. See: Relays and Modules - Powertrain Management/Relays and Modules - Computers and Control Systems/Central Timer Module CENTRAL TIMER MODULE The Durango (DN) utilizes a Central Timer Module (CTM). This system is available in a Base or Highline configuration. The CTM performs most of the typical functions a Body Control Module would perform. The Base and Highline CTM provides the following features: Battery Saver Functions For Exterior and Interior Lamps - Cargo Lamps - Chime Warning - Courtesy Lamps - Dome Lamps - Dome Defeat - Door Ajar Switch Status - Fog Lamps - Head Lamp Time Delay - Intermittent Wiper Controls - Low and High Beam Head Lamps - Optical Horn - Park Lamps Additional features of Highline CTM Central Locking (VTSS) - Door Lock Inhibit - Driver Door Unlock - Enhanced Accident Response - Power Door Locks - Remote Radio - Remote Keyless Entry - Vehicle Theft Alarm (VTSS) Fig. 1 Central Timer Module The Central Timer Module is located behind the left side kick panel. It contains 26-way, 16-way and 12-way connectors. The high-line Central Timer Module (CTM) can also control some features of the audio system when the vehicle is equipped with the optional RAZ radio receiver and remote radio switches. A high-line CTM is used on high-line versions of this vehicle. The CTM combines the functions of a chime/buzzer module, an intermittent wipe module, an illuminated entry module, a remote keyless entry module, and a vehicle theft security Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 126 system module in a single unit. The high-line CTM also controls and integrates many of the additional electronic functions and features included on models with this option. The RAZ radio receiver with a remote radio switch option is one of the features that the CTM controls. The CTM is programmed to send switch status messages over the J185O data bus to control the volume, seek, and pre-set station advance functions of the RAZ radio receiver. The CTM monitors the status of the remote radio switches located on the steering wheel through a hard wired circuit. The CTM then sends the proper switch status messages to the radio receiver. The electronic circuitry within the radio receiver responds to the switch status messages it receives by adjusting the radio settings as requested. In addition, radio receivers connected to the J1850 data bus have several audio system functions that can be diagnosed using a DRB scan tool. Refer to the proper Diagnostic Procedures for more information on DRB testing of the audio systems. Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. Whichever version of the CTM the vehicle is equipped with, it is concealed behind the trim on the left cowl side inner panel below the instrument panel, where it is secured with three screws. The CTM is enclosed in a molded plastic housing with three integral external connector receptacles that connect it to the vehicle electrical system through one take out and connector of the body wire harness, and two take outs and connectors of the instrument panel wire harness. The base version of the CTM is used on base models of this vehicle. These base models are not equipped with the optional power lock system, the Remote Keyless Entry (RKE) system, the rear wiper system, the Vehicle Theft Security System (VTSS), or the remote radio controls. The high-line version of the CTM is used on high-line vehicles that are equipped with one or more of those options not found on base models. The CTM utilizes integrated circuitry and information carried on the Programmable Communications Interface (PCI) data bus network along with many hard wired inputs to monitor many sensor and switch inputs throughout the vehicle. In response to those inputs, the internal circuitry and programming of the CTM allow it to supply the vehicle occupants with audible and visual information, and to control and integrate many electronic functions and features of the vehicle through both hard wired outputs and the transmission of electronic message outputs to other electronic modules in the vehicle over the PCI data bus. The features that the CTM supports or controls include the following: Automatic Door Lock - The high-line CTM provides an automatic door lock feature (also known as rolling door locks). This is a programmable feature. - Battery Protection - The CTM provides a battery saver feature that performs timed load shedding whenever courtesy, reading, visor vanity, center console, glove box, or any exterior lamps are left on with the ignition switch in the OFF position. - Central Locking - The high-line CTM on vehicles equipped with the optional Vehicle Theft Security System (VTSS) includes a central locking/ unlocking feature. - Chimes - All versions of the CTM provide chime service and beep request service through an integral chime tone generator. - Door Lock Inhibit - The high-line CTM provides a power door lock inhibit feature. - Enhanced Accident Response - The high-line CTM provides an optional enhanced accident response feature. This is a programmable feature. - Exterior Light Features - The CTM provides control of park lamps, fog lamps, and headlamps. This includes support for optical horn (also known as flash-to-pass), headlamp time delay, daytime running lamps (DRL - Canada only), and battery saver features. - Interior Light Features - The CTM provides control of courtesy lamps, dome lamps, and the liftgate lamp. This includes support for a timed illuminated entry with fade-to-OFF, interior lighting delay, courtesy illumination defeat, and battery saver features. - Intermittent Wipe Control - The CTM provides control of the intermittent wipe delay, and wipe-after-wash features for the front wiper and washer system. The high-line CTM also provides these same features for the optional rear wiper and washer system. - Panic Mode - The high-line CTM provides support for the optional RKE system panic mode including horn chirp, headlamp flash, and park lamp flash features. - Power Lock Control - The high-line CTM provides the optional power lock system features, including support for the automatic door lock and door lock inhibit modes. - Programmable Features - The CTM provides support for certain programmable features. - Remote Keyless Entry - The high-line CTM provides the optional Remote Keyless Entry (RKE) system features, including support for the RKE Lock (with optional horn chirp and park lamps flash), Unlock (with optional park lamps flash, driver-door- only unlock, and unlock-all-doors), Panic, and illuminated entry modes, as well as the ability to be programmed to recognize up to four RKE transmitters. The RKE horn chirp, park lamps flash, driver- door-only unlock, and unlock-all-doors features are programmable. - Remote Radio Switch Interface - The high- line CTM monitors and transmits the status of the optional remote radio switches on the steering wheel. - Speed Sensitive Intermittent Wipe Control - The CTM provides a speed sensitive front intermittent wipe feature. - Vehicle Theft Security System - The high-line CTM provides control of the optional Vehicle Theft Security System (VTSS) features, including support for the central locking/unlocking mode and control of the Security indicator in the instrument cluster. Hard wired circuitry connects the CTM to the electrical system of the vehicle. These hard wired circuits are integral to several wire harnesses, which are routed throughout the vehicle and retained by many different methods. These circuits may be connected to each other, to the vehicle electrical system and to the CTM through the use of a combination of soldered splices, splice block connectors, and many different types of wire harness terminal connectors and insulators. All versions of the CTM for this model are serviced only as a complete unit. Many of the electronic features in the vehicle controlled or supported by the CTM are programmable using the DRB III scan tool. In addition, the CTM software is Flash compatible, which means it can be reprogrammed using Flash reprogramming procedures. However, if any of the CTM hardware components are damaged or faulty, the entire CTM unit must be replaced. The hard wired inputs or outputs of all CTM versions can be diagnosed using conventional diagnostic tools and methods; however, for diagnosis of the CTM or the PCI data bus, the use of a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 127 The microprocessor-based Central Timer Module (CTM) monitors many hard wired switch and sensor inputs as well as those resources it shares with other electronic modules in the vehicle through its communication over the Programmable Communications Interface (PCI) data bus network. The internal programming and all of these inputs allow the CTM microprocessor to determine the tasks it needs to perform and their priorities, as well as both the standard and optional features that it should provide. The CTM programming then performs those tasks and provides those features through both PCI data bus communication with other electronic modules and through hard wired outputs through a number of driver circuits, relays, and actuators. These outputs allow the CTM the ability to control numerous accessory systems in the vehicle. The CTM operates on battery current received through two fuses in the Junction Block (JB) on two non-switched fused B(+) circuits, a fused ignition switch output (run-start) circuit, and a fused ignition switch output (run-acc) circuit. This arrangement allows the CTM to provide some features regardless of the ignition switch position, while other features will operate only with the ignition switch in the Accessory, ON, and/or Start positions. The CTM receives ground through its connector and take out of the instrument panel wire harness on three separate ground circuits. Two of these circuits are grounded through a take out of the instrument panel wire harness with an eyelet terminal connector that is secured by a nut to a ground stud on the left inner cowl side panel near the CTM, while the third circuit is grounded through a take out of the instrument panel wire harness with an eyelet terminal connector that is secured by a ground screw to the left side of the floor panel transmission tunnel near the Airbag Control Module (ACM). The CTM monitors its own internal circuitry as well as many of its input and output circuits, and will store a Diagnostic Trouble Code (DTC) in electronic memory for any failure it detects. These DTCs can be retrieved and diagnosed using a DRB III scan tool. Refer to the appropriate diagnostic information. Hard Wired Inputs The hard wired inputs to the CTM include the following: Courtesy lamp switch sense - Cylinder lock switch sense - high line with VTSS only - Driver door ajar switch sense - Driver door switch mux - high line with power locks only - Fog lamp switch sense - Front washer pump/motor control - Front wiper park switch sense - Fused B(+) (two circuits) - Fused ignition switch output (run-acc) - Fused ignition switch output (run-start) - Ground (three circuits) - Headlamp switch off sense - High beam switch output - Interior lamp defeat - Intermittent front wiper mode sense - Intermittent front wiper switch signal - Key-in ignition switch sense - Liftgate ajar switch sense - Low beam switch output - Park brake switch sense - Park lamp switch sense - Passenger door ajar switch sense - Passenger door switch mux - high line with power locks only - PCI bus circuit - Radio control mux - high-line with remote radio switches only - Washer switch sense - Wiper park switch sense - Wiper switch mode sense - Wiper switch mode signal Hard Wired Outputs The hard wired outputs of the CTM include the following: Courtesy lamp driver - Door lock relay output - high-line with power locks only - Door unlock relay output - high-line with power locks only - Driver door unlock relay output - high-line with power locks only - Fog lamp relay control - with fog lamps only - Front washer pump/motor control - Front wiper park switch sense - Front wiper relay control - Glove box lamp driver - High beam indicator driver - Horn relay control - high-line with power locks only Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 128 - Interior lamp driver - Left high beam driver - Left low beam driver - Park lamp relay control - Rear wiper park switch sense - high line with rear wiper and washer system only - Rear wiper relay control - high line with rear wiper and washer system only - Right high beam driver - Right low beam driver - VTSS indicator driver - high-line with VTSS only Messaging The CTM uses the following messages received from other electronic modules over the PCI data bus: Airbag Deploy (ACM) - Beep request (CMTC) - Charging System Failure (PCM) - Chime request (EMIC) - Engine RPM (PCM) - OK to Arm VTSS (PCM) - Rear Washer Status (Heater-A/C Control) - Rear Wiper Status (Heater-A/C Control) - Security indicator request (SKIM) - System Voltage (PCM) - Valid/Invalid Key (SKIM) - Vehicle Distance (PCM) - Vehicle Speed (PCM) - Voltage Fault (PCM) The CTM provides the following messages to other electronic modules over the PCI data bus: Door Ajar Status (EMIC) - Liftgate Ajar Status (EMIC) - Park Brake Status (CAB, EMIC, TCM) - Radio Mode (Radio) - Radio Preset Scan (Radio) - Radio Seek Down (Radio) - Radio Seek Up (Radio) - Radio Volume Down (Radio) - Radio Volume Up (Radio) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Testing and Inspection > Audible Warning Device Control Module: Testing and Inspection "Low Line" Central Timer Module (Chime) Test For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. See: Relays and Modules - Powertrain Management/Relays and Modules - Computers and Control Systems/Central Timer Module The hard wired inputs to and outputs from the Central Timer Module (CTM) may be diagnosed and tested using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the CTM. In order to obtain conclusive testing of the CTM, the Programmable Communications Interface (PCI) data bus network and all of the electronic modules that provide inputs to or receive outputs from the CTM must also be checked. The most reliable, efficient, and accurate means to diagnose the CTM, the PCI data bus network, and the electronic modules that provide inputs to or receive outputs from the CTM requires the use of a DRB III scan tool. Refer to the appropriate diagnostic information. The DRB III scan tool can provide confirmation that the PCI data bus network is functional, that all of the electronic modules are sending and receiving the proper messages over the PCI data bus, and that the CTM is receiving the proper hard wired inputs and responding with the proper hard wired outputs needed to perform its many functions. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: The following tests may not prove conclusive in the diagnosis of the Central Timer Module (CTM). The most reliable, efficient, and accurate means to diagnose the CTM requires the use of a DRB III scan tool. Refer to the appropriate diagnostic information. 1. Check the fused B(+) fuses (Fuse 3 - 20 ampere, and Fuse 12 - 20 ampere) in the Power Distribution Center (PDC). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fused B(+) fuses (Fuse 3 - 20 ampere, and Fuse 12 - 20 ampere) in the PDC. If OK, go to Step 3. If not OK, repair the open B(+) circuit between the PDC and the battery as required. 3. Disconnect and isolate the battery negative cable. Disconnect the instrument panel wire harness connector (Connector C3) for the CTM from the CTM connector receptacle. Reconnect the battery negative cable. Check for battery voltage at each of the two fused B(+) circuit cavities of the instrument panel wire harness connector (Connector C3) for the CTM. If OK, disconnect and isolate the battery negative cable, reconnect the instrument panel wire harness connector (Connector C3) for the CTM to the CTM connector receptacle, and go to Step 4. If not OK, repair the open fused B(+) circuit(s) between the CTM and the PDC as required. 4. Check the fused ignition switch output (run-start) fuse (Fuse 11 - 10 ampere) and the fused ignition switch output (run-acc) fuse (Fuse 5 - 20 ampere) in the Junction Block (JB). If OK, go to Step 5. If not OK, repair the shorted circuit or component as required and replace the faulty fuse(s). 5. Reconnect the battery negative cable. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run-start) fuse (Fuse 11 - 10 ampere) and the fused ignition switch output (run-acc) fuse (Fuse 5 20 ampere) in the JB. If OK, go to Step 6. If not OK, repair the open fused ignition switch output (run-start) circuit or fused ignition switch output (run-acc) circuit between the JB and the ignition switch as required. 6. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the instrument panel wire harness connector (Connector C1) for the CTM from the CTM connector receptacle. Reconnect the battery negative cable. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run-start) circuit cavity and the fused ignition switch output (run-acc) cavity of the instrument panel wire harness connector (Connector C1) for the CTM. If OK, go to Step 7. If not OK, repair the open fused ignition switch output (run-start) circuit or fused ignition switch output (run-acc) circuit between the CTM and the JB as required. 7. Turn the ignition switch to the OFF position. Check for continuity between each of the three ground circuits in the instrument panel wire harness connector (Connector C1) for the CTM and a good ground. In each case there should be continuity. If OK, use a DRB III scan tool to perform further diagnosis of the CTM. Refer to the appropriate diagnostic information. If not OK, repair the open ground circuit(s) to ground (G207 or G208) as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Testing and Inspection > Page 131 Audible Warning Device Control Module: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: Before replacing a Central Timer Module (CTM), use a DRB III scan tool to retrieve the current settings for the CTM programmable features. Refer to the appropriate diagnostic information. These settings should be duplicated in the replacement CTM using the DRB III scan tool before returning the vehicle to service. 1. Disconnect and isolate the battery negative cable. 2. Remove the trim from the left cowl side inner panel. Fig. 2 Central Timer Module 3. Disconnect the two instrument panel wire harness connectors and one body wire harness connector from the CTM connector receptacles (Fig. 2). 4. Remove the three screws that secure the CTM to the left cowl side inner panel. 5. Remove the CTM from the left cowl side inner panel. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: Before replacing a Central Timer Module (CTM), use a DRB III scan tool to retrieve the current settings for the CTM programmable features. Refer to the appropriate diagnostic information. These settings should be duplicated in the replacement high-line/premium CTM using the DRB III scan tool before returning the vehicle to service. 1. Position the CTM onto the left cowl side inner panel (Fig. 2). 2. Install and tighten the three screws that secure the CTM to the left cowl side inner panel. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the two instrument panel wire harness connectors and one body wire harness connector to the CTM connector receptacles. 4. Reinstall the trim onto the left cowl side inner panel. 5. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Locations Speedometer Module: Locations The speedometer is located next to the tachometer, just to the right of center in the instrument cluster. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Power Distribution Center Fog Lamp Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 139 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 140 Fog/Driving Lamp Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 141 Fog Lamp Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Horn Relay is located in the Junction Block (JB). Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 145 Horn Relay: Diagrams Junction Block (Front View) Horn Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 146 Horn Relay: Service Precautions WARNING: - ON VEHICLES EQUIPPED WITH AIRBAGS, Refer TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 147 Horn Relay: Description and Operation The horn relay is a electromechanical device that switches battery current to the horn when the horn switch grounds the relay coil. The horn relay is located in the Junction Block (JB), on the left end of the instrument panel in the passenger compartment. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the JB until further diagnosis is completed. See the fuse and relay layout label affixed to the inside surface of the fuse access panel for horn relay identification and location. The horn relay is a International Standards Organization (ISO) micro-relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The ISO micro-relay terminal functions are the same as a conventional ISO relay. However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay. The horn relay cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When the electromagnetic coil is energized, it draws the movable contact away from the normally closed fixed contact, and holds it against the other (normally open) fixed contact. When the electromagnetic coil is de-energized, spring pressure returns the movable contact to the normally closed position. The resistor or diode is connected in parallel with the electromagnetic coil in the relay, and helps to dissipate voltage spikes that are produced when the coil is de-energized. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 148 Horn Relay: Testing and Inspection Fig.2 Horn Relay The horn relay is located in the Junction Block (JB) on the left end of the instrument panel in the passenger compartment of the vehicle. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the JB until further diagnosis is completed. See the fuse and relay layout label affixed to the inside surface of the fuse access panel for horn relay identification and location. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, Refer TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the horn relay from the JB. (Refer to HORN RELAY - REMOVAL) for the procedures. 2. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 4. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, perform the Relay Circuit Test that follows. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair the open circuit to the fuse in the PDC as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. This terminal supplies battery voltage to the horn(s). There should be continuity between the cavity for relay terminal 87 and the horn relay output circuit cavity of each horn wire harness connector at all times. If OK, go to Step 4. If not OK, repair the open circuit to the horn(s) as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay. It is connected to battery voltage and should be hot at all times. Check for battery voltage at the cavity for relay terminal 86. If OK, go to Step 5. If not OK, repair the open circuit to the fuse in the PDC as required. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. It is grounded through the horn switch when the horn switch is depressed. On vehicles equipped with the Remote Keyless Entry (RKE) system, the horn relay coil ground terminal can also be grounded by the Central Timer Module (CTM) in response to certain inputs related to the RKE system or the Vehicle Theft Security System. Check for continuity to ground at the cavity for relay terminal 85. There should be continuity with the horn switch depressed, and no continuity with the horn switch released. If not OK, (Refer to HORN SWITCH DIAGNOSIS AND TESTING). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 149 Horn Relay: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the fuse access panel by inserting a finger in the finger recess molded into the panel and then pulling the panel sharply away from the left outboard end of the instrument panel. 3. See the fuse and relay layout label affixed to the inside of the fuse access panel for horn relay identification and location. 4. Grasp the horn relay firmly and pull it straight out from the JB. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. See the fuse and relay layout label affixed to the inside of the fuse access panel for the proper horn relay location. 2. Position the horn relay in the proper receptacle in the JB. 3. Align the horn relay terminals with the terminal cavities in the JB receptacle. 4. Push in firmly on the horn relay until the terminals are fully seated in the terminal cavities in the JB receptacle. 5. Insert the tabs on the forward edge of the fuse access panel in the notches on the forward edge of the instrument panel fuse access panel opening. 6. Press the rear edge of the fuse access panel in toward the instrument panel until the panel snaps back into place. 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Park Lamp Relay is located in the Junction Block (JB). Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 153 Parking Lamp Relay: Diagrams Junction Block (Front View) Park Lamp Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block Relay Box: Locations Junction Block Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block > Page 159 Relay Box: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block Relay Box: Diagrams Junction Block 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 162 8w-12-3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 163 8w-12-4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 164 8w-12-5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 165 Junction Block C1 Junction Block C2 Junction Block C3 Junction Block C4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 166 Junction Block C5 Junction Block C6 Junction Block C7 Junction Block C8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 167 Junction Block C9 Junction Block C10 Junction Block C11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 168 Junction Block C12 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 169 Relay Box: Diagrams Power Distribution Center 8w-10-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 170 8w-10-3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 171 8w-10-4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 172 8w-10-5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 173 8w-10-6 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 174 8w-10-7 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 175 8w-10-8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 176 8w-10-9 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 177 8w-10-10 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 178 8w-10-11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 179 8w-10-12 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Page 180 Relay Box: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block Relay Box: Application and ID Junction Block Junction Block Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 183 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 184 Relay Box: Application and ID Power Distribution Center Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 185 Relay Box: Description and Operation Fig. 10 Relay And Fuse Block Location RELAY CENTER The relay and fuse block is snap fit onto mounting tabs located on the end of the Junction Block (JB) nearest to the dash panel, under the left outboard end of the instrument panel (Fig. 10). The relay and fuse block provides additional capacity for distribution and control of electrical current for some of the accessory systems that are unique to this vehicle, and which could not be accommodated by the JB or the Power Distribution Center (PDC). The relay and fuse block has cavities for up to four additional blade4ype mini fuses, the electronic combination flasher, and three additional International Standards Organization relays (one standard-type and two micro-type). The relay and fuse block components are accessed for service by removing the steering column opening cover from the instrument panel. The relay and fuse block is then disengaged from the JB mounting tabs and pulled out from under the instrument panel. Service replacement of the relay and fuse block unit requires instrument panel assembly removal. The relay and fuse block unit cannot be repaired and is only serviced as a unit with the instrument panel wire harness assembly. If the relay and fuse block housing or its internal circuits are faulty or damaged, the entire instrument panel wire harness unit must be replaced. The relay and fuse block is integral to the instrument panel wire harness, and all circuits entering or leaving this module do so through the instrument panel wire harness. Internal connection of all of the relay and fuse block circuits is accomplished by hard wiring. Refer to Fuse/Fuse Block for the location of complete circuit diagrams and cavity assignments for the relay and fuse block. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 186 Relay Box: Service and Repair REMOVAL The relay and fuse block is serviced as a unit with the instrument panel wire harness. If any internal circuit of the relay and fuse block or the relay and fuse block housing is faulty or damaged, the entire instrument panel wire harness unit must be replaced. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel assembly from the dash panel. Refer to Instrument Panel Assembly for the instrument panel assembly removal procedures. 3. Disconnect each of the instrument panel wire harness connectors. Refer to Connector Locations for the location of more information on the instrument panel wire harness connector locations. 4. Remove all of the fasteners that secure each of the instrument panel wire harness ground eyelets to the instrument panel components. Refer to Connector Locations for the location of more information on the ground eyelet locations. 5. Disengage each of the retainers that secure the instrument panel wire harness to the instrument panel components. Refer to Connector Locations for the location of more information on the instrument panel wire harness retainer locations. Fig. 11 Relay And Fuse Block Remove/Install 6. Push the relay and fuse block towards the left end of the instrument panel to disengage its mounting slots from the tabs on the Junction Block (JB) (Fig. 11). 7. Remove the relay and fuse block and the instrument panel wire harness from the instrument panel as a unit. INSTALLATION The relay and fuse block is serviced as a unit with the instrument panel wire harness. If any internal circuit of the relay and fuse block or the relay and fuse block housing is faulty or damaged, the entire instrument panel wire harness unit must be replaced. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: If the relay and fuse block is being replaced with a new unit, be certain to transfer each of the fuses, the flasher and the relays from the faulty relay and fuse block to the proper cavities of the replacement relay and fuse block. Refer to Fuse' Fuse Block for the location of complete relay and fuse block circuit diagrams and cavity assignments. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 187 1. Position the relay and fuse block and the instrument panel wire harness onto the instrument panel. 2. Install the relay and fuse block by engaging its mounting slots onto the tabs on the Junction Block (JB). 3. Engage each of the retainers that secure the instrument panel wire harness to the instrument panel components. Refer to Connector Locations for the location of more information on the instrument panel wire harness retainer locations. 4. Install all of the fasteners that secure each of the instrument panel wire harness ground eyelets to the instrument panel components. Refer to Connector Locations for the location of more information on the ground eyelet locations. 5. Reconnect each of the instrument panel wire harness connectors. Refer to Connector Locations for the location of more information on the instrument panel wire harness connector locations. 6. Install the instrument panel assembly onto the dash panel. Refer to Instrument Panel Assembly for the location of the instrument panel assembly installation procedures. 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions Central Timer Module: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 194 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 195 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 196 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 197 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 198 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 199 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 200 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 201 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 202 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 203 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 204 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 205 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 206 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 207 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 208 Central Timer Module: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 209 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 210 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 211 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 212 Central Timer Module: Electrical Diagrams 8w-45-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 213 8w-45-3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 214 8w-45-4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 215 8w-45-5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 216 8w-45-6 (Base) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 217 8w-45-7 (Light Package) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 218 8w-45-8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 219 8w-45-9 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 220 8w-45-10 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 221 8w-45-11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 222 8w-45-12 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 223 8w-45-13 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 224 8w-45-14 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 225 8w-45-15 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information Central Timer Module: Technician Safety Information WARNING: - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. 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. - NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information > Page 228 Central Timer Module: Vehicle Damage Warnings Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. 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, Road Testing A Complaint Vehicle Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE REASSEMBLED. DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB III SCREEN WHILE IN MOTION. DO NOT HANG THE DRB III FROM THE REAR VIEW MIRROR OR OPERATE IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB III. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description Central Timer Module: Description and Operation Sytem Description The body system on the 2001 DN consists of a combination of modules that communicate over the PCI bus (Programmable Communication Interface multiplex system). Through the PCI bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all information to perform its function. It will only respond to messages "addressed" to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. All of the information about the functioning of all the systems is organized, controlled, and communicated by the PCI bus, which is described in the vehicle communication of this general information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 231 Central Timer Module: Description and Operation Functional Operation Part 1 of 2 For additional information on the Base CTM refer to Instrument Panel, Gauges and Warning Indicators / Audible Warning Device. See: Instrument Panel, Gauges and Warning Indicators/Audible Warning Device AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. The Airbag Control Module (ACM) is an electronic module that monitors the airbag system for proper operation, stores diagnostic trouble code (DTCs), controls the airbag warning lamp and contains the sensor and actuator that is responsible for airbag deployment. There are no external impact sensors. The ACM is mounted on a special bracket that is fastened to the floor of the truck at the bottom of the instrument panel. It is located forward of the console. The ACM provides diagnostic information (DTCs) to the technician through the DRB III via the PCI bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp is driven with messages relayed to the Electro/Mechanical Instrument Cluster (EMIC) from the ACM via the PCI bus. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Whenever the ignition key is turned to the "run" or "start" position, the airbag control module performs a lamp check by turning the AIRBAG warning lamp ON for 6 - 8 seconds. If the lamp remains OFF, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains ON, there could be an active fault in the system or the circuit that operates the lamp may be shorted to ground. If the lamp comes ON and stays ON for a period longer than 6 - 8 seconds, then goes OFF, there is usually an intermittent problem in the system. WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. 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. - NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. Seat Belt Tensioner Front seat belt systems incorporate Tensioner Modules (SBT). At the onset of an impact event each tensioner uses a pyrotechnic device, which is triggered simultaneously with the airbags, to rapidly retract the seat belts. With the slack removed, the occupant's forward motion in an impact will be reduced as will the likelihood of contacting interior components. After an impact that deploys the airbag, the seat belt tensioner assembly must be replaced. The ACM module monitors the Seat Belt Tensioners circuit resistance and reports active and stored DTC's if any problem is found. Airbag Diagnostic Trouble Codes Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB III. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures, diagnostic trouble codes are used as a diagnostic tool. Active Codes The code becomes active as soon as the malfunction is detected and stored after one minute of occurrence or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 232 of 12 seconds or as long as the malfunction is present. Stored Codes Airbag codes are automatically stored in the ACM's memory after one minute of occurrence or when the ignition is turned OFF. The exception is the "Loss of Ignition Run Only" code which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored as long as the malfunction exists. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, that diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "ON" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. AUDIO SYSTEM The factory installed radio receiver communicates on the Programmable Communication Interface (PCI) data bus network through a separate two-way wire harness connector. This is used for the remote radio switches that are mounted to the steering wheel, and also used for radio diagnosis with the DRB III. The remote radio switches are resistor multiplexed units that are hard wired to the CTM through the clockspring. The CTM monitors the status of the remote radio switches and sends the proper switch status messages on the PCI data bus network to the radio receiver. The electronic circuitry within the radio is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. When troubleshooting output shorts or "output" error messages, the following applies: On radios without an external amplifier, the term "output" refers to the path between the radio and the speaker. This type of circuit can be monitored all the way through the speaker connections by the radio assembly. When the radio displays a shorted output DTC with this type of system, the speaker, radio or wiring could be at fault. The output DTC could refer to a front or rear output or a left or right output. The reason for the difference is the pairing of the output sections of the radio. Some are paired left and right, others are paired front and rear. On radios with an external amplifier, the term "output" refers to the circuit between the radio connector and the amplifier. The radio is capable of monitoring only this portion and can tell nothing about the circuit between the amplifier and the speakers. Consequently, a shorted output DTC on this type of system would only refer to this circuit. A faulty speaker could not cause this DTC. CENTRAL TIMER MODULE The Durango (DN) utilizes a Central Timer Module (CTM). This system is available in a Base or Highline configuration. The CTM performs most of the typical functions a Body Control Module would perform. The Base and Highline CTM provides the following features: Battery Saver Functions For Exterior and Interior Lamps - Cargo Lamps - Chime Warning - Courtesy Lamps - Dome Lamps - Dome Defeat - Door Ajar Switch Status - Fog Lamps - Head Lamp Time Delay - Intermittent Wiper Controls - Low and High Beam Head Lamps - Optical Horn - Park Lamps Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 233 Additional features of Highline CTM - Central Locking (VTSS) - Door Lock Inhibit - Driver Door Unlock - Enhanced Accident Response - Power Door Locks - Remote Radio - Remote Keyless Entry - Vehicle Theft Alarm (VTSS) The Central Timer Module is located behind the left side kick panel. It contains 26-way, 16-way and 12-way connectors. CHIME SYSTEM The chime system is built into the CTM. There are two chime rates, Low: 50 chimes per minute for reminders and High: 180 chimes per minute for serious conditions that require immediate attention. The high rate chime sounds when the key is left in the ignition and the driver's door is open or if the headlights or the courtesy lights are left on. The low rate chime sounds for any of the other conditions. There is a variable rate feature that allows the chime to sound continuously for key-in and headlamp warning as long as the door is open. The seat belt warning chime is activated for six seconds, and all other chime conditions will activate the chime once at the same time the warning light on the cluster is illuminated. The Chime will sound for the following conditions: Ignition OFF key in ignition, driver's door open - Ignition OFF, headlamps ON, driver's door open - Ignition OFF, courtesy lamps ON, driver's door open - Seat belt warning (after prove-out) - Malfunction Indicator lamp (MIL) illuminated (after prove-out) - Airbag lamp illuminated (after prove-out) - Check gauges lamp - Low fuel warning - Low washer fluid lamp - Door ajar warning - Transmission temperature lamp - Turn signal on reminder warning - Button pushed on compass mini-trip computer COMPASS MINI-TRIP COMPUTER (CMTC) This system, located in the overhead console, displays information on outside temperature, compass direction and trip information. Compass and Temperature Display This display provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. Trip Odometer (ODO) Shows the distance traveled since the last reset. Average Fuel Economy (AVE ECO) Shows the average fuel economy in MPG (miles per gallon) or L/100 Km since the last reset. Instant Fuel Economy Shows the fuel economy for the last few seconds in MPG or L/100 Km. Distance to Empty (DTE) Shows the estimated distance that can be traveled with the fuel remaining in the tank. This is calibrated using the MPG for the last few minutes. Elapsed Time (ET) Shows the accumulated ignition ON time since the last reset. Step Button Press this button to cycle through all the mini-trip computer displays. US/M Button Press this button to convert all vehicle displays from US to Metric to US. To Reset the Display Press the Step and US/M buttons simultaneously for at least two seconds and all resettable conditions will be reset. This will occur only if a resettable function (AVG ECO, ECO, ET) is currently being displayed. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 234 Automatic Compass Calibration This compass is self calibrating which eliminates the need to manually set the compass. When the vehicle is new, the compass may appear erratic and the CAL symbol will be displayed. After completing three 360' turns in an area free from large metal or metallic objects, the CAL symbol will turn OFF and the compass will function normally. Compass Variance Compass Variance is the difference between Magnetic North and Geographic North. In some areas of the country, the difference between Magnetic and Geographic North is great enough to cause the compass to give false readings. If this occurs, the compass variance must be set. To Set the Variance Turn the ignition ON and set display to Comp./Temp. while pressing the US/M button, press the STEP button for approximately five seconds. The "VAR" symbol will light and the last variance zone number will be displayed. Press the US/Metric Button to select the proper variance zone as shown on the map. Press the Step button to set the new variance zone and resume normal operation. ELECTRO/MECHANICAL INSTRUMENT CLUSTER (EMIC) The Instrument Cluster contains a Fuel, Voltmeter, Coolant Temp, and Oil Pressure gauge, a Tachometer and a Speedometer. With the exception of the Voltmeter, the cluster positions the gauges with PCI Bus messages received from the PCM. The Voltmeter operates directly off of the Fused B+ Switched Ignition Output circuit that supplies ignition voltage for the cluster. The Instrument Cluster also contains warning indicators that are illuminated by hard wired inputs or by messages received from other modules on the PCI Bus. The Trip/Total Odometer is a Vacuum Fluorescent Display (VF) that is controlled by PCI Bus messages received from the PCM. The cluster illumination lamps are hard wired in the Instrument Cluster. When the Park or Headlamps are turned ON, the cluster receives a dimmed battery feed from the Headlamp Switch. The cluster I/O Processor controls the VF display dimming and also sends dimming level messages on the PCI Bus. The EMIC will communicate with the DRB III to display PCI Engine Info, PCI Bus Info, and certain input/outputs. Cluster diagnostic capabilities that the DRB III will actuate are limited to the Cluster Calibration Points for the gauges. The DRB III can also extract active and stored Diagnostic Trouble Codes (DTC) from the Instrument Cluster. The EMIC is also capable of performing a diagnostic Self-Test that is actuated by depressing and holding the Odometer trip reset stalk while cycling the ignition from the OFF to the ON position. After the cluster Odometer displays CHEC, releasing the reset stalk begins the test. The cluster will then position all of the gauges at specified calibration points and will illuminate all the PCI Bus controlled indicators. The cluster will also illuminate each segment of the VF display. The EMIC can verify communications with the PCM, ID the module, or change the country code using the DRB III. ENHANCED ACCIDENT RESPONSE (HIGHLINE CTM ONLY) If the Airbag Control Module (ACM) deploys the airbags, a message is transmitted over the PCI bus to the CTM module to unlock the doors. The interior lights will be turned ON when the vehicle speed message on the PCI bus indicates 0 mph or the message is not present. In addition to unlocking the doors, the door lock feature will be disabled for a predetermined amount of time following the deployment. Once the ignition key has been cycled to the "OFF" position, normal operation will resume. EXTERIOR LIGHTING The low and high beam headlamps are controlled directly by an output from the Central Timer Module (CTM). The park lamps and fog lamps (on vehicle so equipped) are controlled via external relays that are energized by the CTM. The headlamp switch provides the control signal through the multifunction switch to the CTM, which indicates low or high beam operation. The Optical Horn (Flash to Pass) feature operates both the high beam and low beam headlamps. The CTM provides the Headlamp Time Delay feature. To start the delay, turn the ignition OFF while the headlamps are ON. Then turn the headlamp switch to the OFF position. This has to be done within 45 seconds of the ignition being turned OFF. The headlamps will remain ON for 60 ± 5 seconds. If during this delay period the headlamp switch is turned ON and then OFF, or ignition switch is turned ON delay will be canceled and they will turn OFF immediately. During the delay period, only headlamps are turned ON and park lamps/fog lamps are turned OFF. The CTM also provides battery protection to avoid wearing down the battery if the customer leaves the park lamps or headlamps ON for extended period of time with the ignition OFF. If the park lamps or headlamps remain ON for more than 5 minutes while the ignition is OFF, the headlamps and park lamps shall be turned off and the input causing the lamps to be ON will be ignored until the input is corrected. Once the 5 minute timeout has extinguished the headlamps and park lamps, any change in the ignition switch, door ajar switches, headlamps switch or park lamp switch will reset the 5 minute timer and return the headlamps and park lamps to normal operation. Part 2 of 2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 235 HEATING & A/C SYSTEM The all-new heating and air conditioning system for DN provides more heating and cooling capacity than in previous years. Depending on the model, either a Dual-Zone Air Conditioning System or a Three-Zone Air Conditioning System is currently available in these vehicles. Air Distribution (Front) The front compartment HVAC unit has four fully adjustable instrument panel outlets. Side-window demister outlets in the instrument panel eliminate the need for door ducts and door-to-instrument panel seals. A single central mounted outlet delivers air for defrosting the windshield. Two outlets, one on each side of the center console underneath the instrument panel, provide airflow to the driver floor area and to the front seat passenger floor area. While two additional outlets, one on each side of the center console near the rear of the front seats, distribute both heated and cooled air across the floor to the intermediate seat passengers. Ducts in the center of the vehicle underneath the carpet deliver air from the front compartment HVAC unit to the two intermediate passenger outlets. Door Actuator Control A simplified control system for operation of the mode, recirculation, and temperature control actuators provides positive positioning without the complexity of feedback from position sensors. The A/C - Heater Control Module knows the number of operating actuator revolutions required for full door travel as well as the number of actuator commutator pulses per revolution. Using these parameters, the A/C - Heater Control Module runs the actuator for the number of commutator pulses that correspond to the desired door position. To maintain accuracy, the system recalibrates itself periodically at known zero and full travel conditions. The dual sliding Blend switches have multiple detents to control the full range of temperature that the system can produce in any mode. On Dual-Zone systems, the upper slide pot controls the driver-side blend door and the lower slide pot controls the passenger-side blend door. On Three-Zone systems, the upper slide pot controls the driver-side blend door, while the lower slide pot controls the passenger-side blend door and the rear A/C - heater unit blend door. The single rotary Mode switch has 12 detents to either direct airflow to the panel outlets, to a mix of floor and panel outlets, to the floor outlets, to a mix of floor and defrost outlets, or to the defrost outlet. Rotating the Mode switch to either of the two MAX positions results in the A/C - Heater Control Module sending a signal to the recirculation actuator to close the fresh-air door. While rotating the Mode switch to any other position results in the A/C - Heater Control Module sending a signal to the recirculation actuator to open the fresh-air door. When the Blower switch is OFF, the A/C - Heater Control Module closes the fresh-air door to prevent outside air from entering the vehicle. On Three- Zone systems, the Mode switch also controls the rear A/C - heater unit mode door, which directs rear airflow either to the right quarter trim panel outlet or to the overhead outlets. Front Blower Control The front blower circuitry employs a new resistor technology to control front blower speed. Called the "credit card" resistor, the device looks much like its name in that it is thin and compact like a credit card. The credit card resistor, like the coil resistor used in previous years, mounts inside the front HVAC housing assembly in the airflow path. However, unlike the coil resistor, the credit card resistor offers much less airflow restriction. A/C Operation The A/C - Heater Control Module monitors the temperature of the evaporator to keep it just above freezing for maximum cooling and dehumidification. A thermistor (temperature variable resistor) placed between the evaporator fins provides the signal for the control. The Powertrain Control Module (PCM) cycles the compressor on and off with a signal from the A/C - Heater Control Module. Heater Operation To assist the HVAC system in maintaining a consistent and optimum heat output at low vehicle speeds, an electric coolant pump operates under specific conditions to keep a steady flow of hot coolant circulating through the heater circuit. The A/C - Heater Control Modules controls the operation of the electric coolant pump. The pump runs when all of the following conditions are met: When the vehicle's speed is below 27 Km/h (17 mph), the coolant temperature is between 65.5 °C and 110 °C (150 °F and 230 °F), and the blend control is set above 60% reheat. The A/C - Heater Control Module turns the pump OFF if any one of the following conditions occur: The vehicle speed rises above 48.3 Km/h (30 mph). The coolant temperature drops below 65.5 °C (150 °F). The coolant temperature rises above 110 °C (230 °F). The blend control is set below 60% reheat. A/C - Heater Control (Rear) The Three-Zone system allows the intermediate seat occupants to regulate the air temperature and the fan speed of the rear unit from the rotary controls on the headliner mounted Rear A/C - Heater Control. HVAC Diagnostics The A/C - Heater Control Module is fully addressable with the DRB III. Two of the Control Module's diagnostic capabilities that the DRB III will actuate include the A/C Cool down Test to test A/C system performance and the HVAC Door Recalibration Test to determine actuator travel span. After performing either test, the Control Module will display one or more messages on the DRB III screen. The message will indicate either that the HVAC system passed the test or that there is a fault currently active in the HVAC system. The DRB III can also extract active and stored Diagnostic Trouble Codes (DTCs) from the control module. Active DTCs are faults that currently exit in the HVAC system. Stored DTCs are faults that occurred in the HVAC system since the control module received the last "clear diagnostic info" message. INTERIOR LIGHTING Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 236 The Courtesy lights and illuminated entry feature are controlled by the Central Timer Module (CTM). The CTM will activate the courtesy lamps, including Map Lights and the Dome Lights when either the dome lamp switch is turned ON or a door is opened. The courtesy lamps will fade to OFF immediately when all doors are closed with the dome lamp switch in the OFF position. The illuminated entry feature operates under the following conditions: RKE "unlock" - Driver/Passenger door is opened - Unlocking either the driver or passenger using the key (vehicles equipped with security system) - The dome lamp switch is turned ON Once activated, the illuminated entry will "fade to OFF" after 3 to 5 seconds under the following conditions: All doors are closed and: RKE "lock signal is received or - Manual actuated power "lock" signal is received or - Ignition switch is turned to the ON position or - 30 seconds have elapsed without any other action Addition RKE unlock actuation before the expiration of illuminated entry will not reset timer. Opening any door before the 30 second timer expires, will reset the entry time to 30 seconds and the illuminated entry timer will not begin counting down again until all doors are closed. The Cargo lamps are controlled by the CTM. Placing the dome lamp switch in the cargo lamp position grounds an input to the CTM. The CTM then sends voltage to the cargo lamps. The Interior lamp defeat feature will not allow any interior lamp to be turned ON. This is accomplished through an input to the CTM from the dome lamp switch. The CTM provides battery protection by shutting down the interior lamps due to the following. Leaving a door open, dome lamp switch ON, reading/vanity lamp switch ON or glove box door open for more than 15 minutes while the ignition is OFF. POWER DOOR LOCKS/REMOTE KEYLESS ENTRY The CTM controls the door lock actuator assemblies to handle locking and unlocking with the key fob or interior switch. Vehicles that are equipped with the Vehicle Theft Security System will also have the central locking feature. With the central locking feature, when the cylinder lock switch is turned to the lock position all the doors will lock. For unlocking, if the key is turned to the unlock position once, only that door will unlock. If the key is then turned a second time to the unlock position, all the doors will unlock. There is also a door lock inhibit feature that prevents power locking of the doors if the ignition is OFF and the key is in the ignition. Automatic or "rolling locks" are included as a programmable feature. If the vehicle is moving approximately 15 mph and approximately 10 degrees of throttle opening is seen by the PCM, (the PCM will send this info to the CTM via the PCI bus) indicating acceleration, the CTM will cycle the lock actuators to lock the doors. The highline CTM provides for Remote Keyless Entry (RKE) The RKE system is placed in the programming mode by the DRB III, or by the customer program features. The system will store up to four key fob codes. Two fobs are supplied with the truck, additional fobs may be purchased through the parts department. Through the DRB III, erasing and programming of one key fob without deleting the others is possible. If the key fob is stolen, all the fob codes stored previously may be erased to provide the owner of the vehicle with an extra sense of security. VEHICLE COMMUNICATION The Programmable Communication Interface or PCI Bus is a single wire multiplexed network capable of supporting binary encoded messages shared between multiple modules. The PCI bus circuit is identified as D25 and is violet with a yellow tracer. Additional tracer colors may be added to the yellow in order to distinguish between different module connections. The modules are wired in parallel. Connections are made in the harness using a splice. The splice called the Diagnostic Junction Port, serves as the "Hub" of the bus. The Diagnostic Junction Port provides an access point to isolate most of the modules on the bus in order to assist in diagnosing the circuit. The following modules are used on the DN: Airbag Control Module - A/C Heater Control - Central Timer Module - Controller Antilock Brake - Compass Mini-Trip Computer - Electro/Mechanical Instrument Cluster - Powertrain Control Module - Radio Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 237 - Sentry Key Immobilizer Module - Transfer Case Control Module - Transmission Control Module Each module provides its own bias and termination in order to transmit and receive messages. The bus voltage is at zero volts when no modules are transmitting and is pulled up to about seven and a half volts when modules are transmitting. The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRB III lab scope. The 12v square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between zero and about seven and a half volts. Refer to the figure for some typical displays. The PCI Bus failure modes are broken down into two categories. Complete PCI Bus Communication Failure and individual module no response. Causes of complete PCI Bus Communication Failure include a short to ground or battery on the PCI circuit. Individual module no response can be caused by an open circuit at either the Diagnostic Junction Port or the module, or an open battery or ground circuit to the affected module. Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: All gauges on the EMIC stay at zero - All telltales on EMIC illuminate - EMIC backlighting at full intensity - Dashed lines in the Compass Mini-Trip Computer display Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 238 - No response received from any module on the PCI bus (except the PCM) - No start (if equipped with Sentry Key immobilizer) Symptoms of Individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRB III. Diagnosis starts with symptom identification. If a complete PCI Bus Communication Failure is suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRB III. If any modules are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI circuit or power supply and ground circuits. The DRB III may display "BUS +A SIGNAL OPEN" or "NO RESPONSE" to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRB III and in no way indicates whether or not the PCI bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped. VEHICLE THEFT SECURITY SYSTEM The VTSS system monitors the door ajar switches, and ignition switch to detect unauthorized entry into the vehicle. Once the vehicle is "armed", any one of these inputs can cause the VTSS system to be tripped. Once tripped, the horn and lights will pulse for 3 minutes and if an attempt is made to start the engine with a non-programmed SKIM key, it will start and stall. If the trigger condition is still present, the lights will continue to flash for an additional 15 minutes, after which the system will stop pulsing the lights and return to the "armed" state. The cause of the last 4 alarm triggers is stored by the CTM and may be retrieved by the DRB III. The system may be disarmed by either an unlock command from a valid RKE key fob by using a key in either door, or by using a valid SKIM key in the ignition. The door key cylinders are equipped with disarm switches. There is also a VTSS lamp on the dash that provides information to the driver about the state of the vehicle theft system. WINDSHIELD WIPER SYSTEM The DN truck is equipped with speed sensitive intermittent wipers. The low and high speeds are controlled through the wiper stalk switch. The intermittent portion of the wiper control is handled by the CTM through the intermittent wiper relay. When the module detects a decrease in delay time as selected by the driver, an immediate wipe of the windshield takes place and the new delay interval is implemented. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Central Timer Module: Symptom Related Diagnostic Procedures Non-Trouble Code Procedures For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. The hard wired inputs to and outputs from the Central Timer Module (CTM) may be diagnosed and tested using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the CTM. In order to obtain conclusive testing of the CTM, the Programmable Communications Interface (PCI) data bus network and all of the electronic modules that provide inputs to or receive outputs from the CTM must also be checked. The most reliable, efficient, and accurate means to diagnose the CTM, the PCI data bus network, and the electronic modules that provide inputs to or receive outputs from the CTM requires the use of a DRB III scan tool. Refer to the appropriate diagnostic information. The DRB III scan tool can provide confirmation that the PCI data bus network is functional, that all of the electronic modules are sending and receiving the proper messages over the PCI data bus, and that the CTM is receiving the proper hard wired inputs and responding with the proper hard wired outputs needed to perform its many functions. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: The following tests may not prove conclusive in the diagnosis of the Central Timer Module (CTM). The most reliable, efficient, and accurate means to diagnose the CTM requires the use of a DRB III scan tool. Refer to the appropriate diagnostic information. 1. Check the fused B(+) fuses (Fuse 3 - 20 ampere, and Fuse 12 - 20 ampere) in the Power Distribution Center (PDC). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fused B(+) fuses (Fuse 3 - 20 ampere, and Fuse 12 - 20 ampere) in the PDC. If OK, go to Step 3. If not OK, repair the open B(+) circuit between the PDC and the battery as required. 3. Disconnect and isolate the battery negative cable. Disconnect the instrument panel wire harness connector (Connector C3) for the CTM from the CTM connector receptacle. Reconnect the battery negative cable. Check for battery voltage at each of the two fused B(+) circuit cavities of the instrument panel wire harness connector (Connector C3) for the CTM. If OK, disconnect and isolate the battery negative cable, reconnect the instrument panel wire harness connector (Connector C3) for the CTM to the CTM connector receptacle, and go to Step 4. If not OK, repair the open fused B(+) circuit(s) between the CTM and the PDC as required. 4. Check the fused ignition switch output (run-start) fuse (Fuse 11 - 10 ampere) and the fused ignition switch output (run-acc) fuse (Fuse 5 - 20 ampere) in the Junction Block (JB). If OK, go to Step 5. If not OK, repair the shorted circuit or component as required and replace the faulty fuse(s). 5. Reconnect the battery negative cable. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run-start) fuse (Fuse 11 - 10 ampere) and the fused ignition switch output (run-acc) fuse (Fuse 5 20 ampere) in the JB. If OK, go to Step 6. If not OK, repair the open fused ignition switch output (run-start) circuit or fused ignition switch output (run-acc) circuit between the JB and the ignition switch as required. 6. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the instrument panel wire harness connector (Connector C1) for the CTM from the CTM connector receptacle. Reconnect the battery negative cable. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run-start) circuit cavity and the fused ignition switch output (run-acc) cavity of the instrument panel wire harness connector (Connector C1) for the CTM. If OK, go to Step 7. If not OK, repair the open fused ignition switch output (run-start) circuit or fused ignition switch output (run-acc) circuit between the CTM and the JB as required. 7. Turn the ignition switch to the OFF position. Check for continuity between each of the three ground circuits in the instrument panel wire harness connector (Connector C1) for the CTM and a good ground. In each case there should be continuity. If OK, use a DRB III scan tool to perform further diagnosis of the CTM. Refer to the appropriate diagnostic information. If not OK, repair the open ground circuit(s) to ground (G207 or G208) as required. Chime Inoperative At All Times Test 1 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 241 SYMPTOM CHIME INOPERATIVE AT ALL TIMES POSSIBLE CAUSES - CTM - Chime inoperative Chime Inoperative With Drivers Seat Belt Unfastened Tests 1 - 4 SYMPTOM CHIME INOPERATIVE WITH DRIVER SEAT BELT UNFASTENED POSSIBLE CAUSES - Seat belt switch status wrong - Seat belt switch shorted - Seat belt indicator driver wire short to ground - Instrument cluster - seat belt switch shorted Chime Inoperative With Key In Ignition and Driver's Door Open Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 242 Tests 1 - 4 Test 5 SYMPTOM CHIME INOPERATIVE WITH KEY IN IGNITION, DRIVER'S DOOR OPEN POSSIBLE CAUSES - Driver door ajar status - Ignition switch ground circuit open - Key-in ignition switch open - Key-in ignition switch sense circuit open - Central timer module Chime Inoperative, Exterior/Interior Lamps On, Driver Door Open Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 243 Tests 1 - 2 SYMPTOM CHIME INOPERATIVE WITH EXTERIOR OR INTERIOR LAMPS ON WITH DRIVER DOOR OPEN POSSIBLE CAUSES - DRB check driver door ajar - CTM-chime inoperative with headlamp switch - Operation of exterior or interior lighting system Chime Sounds With Driver Seat Belt Fastened Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 244 Tests 1 - 4 Test 5 SYMPTOM CHIME SOUNDS WITH DRIVER SEAT BELT FASTENED POSSIBLE CAUSES - Seat belt switch status wrong - Seat belt switch open - Ground wire open - Seat belt indicator driver wire open - Instrument cluster - seat belt sense open Chime Sounds With Drivers Door Open and Key Removed From Ignition Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 245 Tests 1 - 4 SYMPTOM CHIME SOUNDS WITH DRIVER'S DOOR OPEN, KEY REMOVED POSSIBLE CAUSES - Operation of exterior or interior lighting system - Key-in ignition switch shorted - Key-in ignition SW sense short to ground - Central timer module - key-in ignition shorted Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 246 Central Timer Module: Component Tests and General Diagnostics Road Testing A Complaint Vehicle ROAD TEST WARNINGS Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the test drive, do not try to read the DRB III screen while in motion. Do not hang the DRB III from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB III. Six Step Troubleshooting Procedure SIX-STEP TROUBLESHOOTING PROCEDURE Diagnosis is done in six basic steps: 1. Verification of complaint 2. Verification of any related symptoms 3. Symptom analysis 4. Problem isolation 5. Repair of isolated problem 6. Verification of proper operation Vehicle Preparation For Testing VEHICLE PREPARATION FOR TESTING Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 247 Central Timer Module: Scan Tool Testing and Procedures DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB III will display one of only two error messages: User-Requested WARM Boot (Press MORE and NO at the same time) User-Requested COLD Boot (Press MORE and YES at the same time) If the DRB III should display any other error message, record the entire display and call the S.T.A.R. Center for information and assistance. DRB III DOES NOT POWER UP If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB III. If all connections are proper between the DRB III and the vehicle or other devices, and the vehicle battery is fully charged, and inoperative DRB III may be the result of faulty cable or vehicle wiring. For a blank screen, refer to the appropriate body diagnostics. DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition SOME DISPLAY ITEMS READ "---" This is caused by scrolling the DRB III display a single line up or down. The line which was scrolled onto the screen might read "---". Use the Page Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 248 Down or Page Up function to display the information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Page 249 Central Timer Module: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: Before replacing a Central Timer Module (CTM), use a DRB III scan tool to retrieve the current settings for the CTM programmable features. Refer to the appropriate diagnostic information. These settings should be duplicated in the replacement CTM using the DRB III scan tool before returning the vehicle to service. 1. Disconnect and isolate the battery negative cable. 2. Remove the trim from the left cowl side inner panel. Fig. 2 Central Timer Module 3. Disconnect the two instrument panel wire harness connectors and one body wire harness connector from the CTM connector receptacles. 4. Remove the three screws that secure the CTM to the left cowl side inner panel. 5. Remove the CTM from the left cowl side inner panel. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: Before replacing a Central Timer Module (CTM), use a DRB III scan tool to retrieve the current settings for the CTM programmable features. Refer to the appropriate diagnostic information. These settings should be duplicated in the replacement high-line/premium CTM using the DRB III scan tool before returning the vehicle to service. 1. Position the CTM onto the left cowl side inner panel. 2. Install and tighten the three screws that secure the CTM to the left cowl side inner panel. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the two instrument panel wire harness connectors and one body wire harness connector to the CTM connector receptacles. 4. Reinstall the trim onto the left cowl side inner panel. 5. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Page 250 Central Timer Module: Tools and Equipment DRB III (Diagnostic Read-out Box) Jumper Wires Ohmmeter Voltmeter Test Light Diagnostic Junction Port Tester 8310 Airbag Load Tool 8443 Airbag Load Tool Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Customer Interest: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts Powertrain Control Module: Customer Interest A/T - 45RFE/545RFE Harsh Upshifts/Downshifts NUMBER: 18-025-01 GROUP: Vehicle Performance DATE: October 15, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-09-00, DATED SEPTEMBER 15, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. **ASTERISKS** HAVE BEEN USED TO HIGHLIGHT CHANGES. THIS BULLETIN ADDS A MODEL YEAR AND REQUIRES A REPROGRAMMING OF THE 1999 AND 2000 GRAND CHEROKEE POWERTRAIN CONTROL MODULE (PCM). SUBJECT: 45RFE **and 545RFE Shift** Quality Enhancements for the** 2-3, 4-5, and 5-4** Shifts OVERVIEW: This bulletin involves selectively erasing and reprogramming the **Transmission Control Module (TCM) with new software: '99-'01 WJ (PN 05019701AC Ver 9.3), '00 AN/DN (PN 05018454AB Ver 9.1), or '01 AN/DN (PN 56028285A1 Ver 8.4), and requires reprogramming of the Powertrain Control Module (PCM) for the 1999 and 2000 Grand Cherokees only (with calibration 99Cal20 (1999) or 00Cal17 (2000).** NOTE: THE 2001 GRAND CHEROKEE DOES NOT REQUIRE REPROGRAMMING OF THE PCM AS IT IS ALREADY AT THE CORRECT CALIBRATION LEVEL. NOTE: WHENEVER A PCM OR TCM IS REPLACED OR REPROGRAMMED, THE SOFTWARE OF THE PCM MUST BE VERIFIED AS HAVING THE LATEST REVISION LEVEL. MODELS: 2000 (AN) Dakota **2001** 2000 (DN) Durango **2001** 1999 (WJ) Grand Cherokee **2001 ** NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 4.7L ENGINE AND A 45RFE **OR 545RFE** TRANSMISSION. SYMPTOM/CONDITION: Some vehicles **may exhibit one or more of the following performance conditions **: 1. A harsh 2-3 upshift causing a powertrain clunk or shudder when accelerating. 2. **A harsh 4-5 upshift ('01 Grand Cherokee only).** 3. **A harsh 5-4 downshift ('01 Grand Cherokee only).** NOTE: THIS REVISION TO THE TCM SOFTWARE ADDRESSES THE ABOVE SHIFT QUALITY CONDITIONS FOR ALL VEHICLES AND, ADDS A FINAL GEAR RATIO TO THE **1999 AND 2000 MY** GRAND CHEROKEE TRANSMISSION ONLY. (2001 MY GRAND CHEROKEE ALREADY HAS THIS UPGRADE.) NOTE: TO MAINTAIN EMISSIONS COMPLIANCE, GRAND CHEROKEE VEHICLES THAT ARE EQUIPPED WITH A FEDERAL EMISSION SYSTEM (SALES CODE NAA) MUST HAVE THEIR PCM REPROGRAMMED. IF THE SOFTWARE LEVEL IS AT OR HIGHER THAN THOSE IN THE OVERVIEW ABOVE, OR IF THE GRAND CHEROKEE HAS A CALIFORNIA EMISSIONS SYSTEM (SALES CODE NAE), REPROGRAMMING IS NOT NECESSARY. DIAGNOSIS PROCEDURES: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRBIII(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 performing this repair. If no DTC's are present, and the above symptom has been experienced, perform the Repair Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Customer Interest: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts > Page 259 Procedure. NOTE: **IF OTHER PERFORMANCE ISSUES REMAIN AFTER THE REPAIR PROCEDURE HAS BEEN PERFORMED THEY DO NOT RELATE TO THIS BULLETIN. REFER TO THE PROPER SERVICE OR DIAGNOSTIC PROCEDURES MANUAL(S) FOR FURTHER ASSISTANCE.** PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD **2093 OR HIGHER AND DRB III(R) VERSION 52.3 WILL BE IN THE DEALERSHIPS ON OCTOBER 15, 2001.)** REPAIR PROCEDURE: 1. Log onto the MDS2 (Mopar Diagnostic System). 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III(R), MDS2, AND VEHICLE ESTABLISH COMMUNICATION. 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. 3. Push the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) 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. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. 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, 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 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Customer Interest: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts > Page 260 7. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 8. 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > All Technical Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Powertrain Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > All Technical Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 266 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > All Technical Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 267 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > All Technical Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 268 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > All Technical Service Bulletins for Powertrain Control Module: > 18-025-01 > Oct > 01 > A/T 45RFE/545RFE Harsh Upshifts/Downshifts Powertrain Control Module: All Technical Service Bulletins A/T - 45RFE/545RFE Harsh Upshifts/Downshifts NUMBER: 18-025-01 GROUP: Vehicle Performance DATE: October 15, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-09-00, DATED SEPTEMBER 15, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. **ASTERISKS** HAVE BEEN USED TO HIGHLIGHT CHANGES. THIS BULLETIN ADDS A MODEL YEAR AND REQUIRES A REPROGRAMMING OF THE 1999 AND 2000 GRAND CHEROKEE POWERTRAIN CONTROL MODULE (PCM). SUBJECT: 45RFE **and 545RFE Shift** Quality Enhancements for the** 2-3, 4-5, and 5-4** Shifts OVERVIEW: This bulletin involves selectively erasing and reprogramming the **Transmission Control Module (TCM) with new software: '99-'01 WJ (PN 05019701AC Ver 9.3), '00 AN/DN (PN 05018454AB Ver 9.1), or '01 AN/DN (PN 56028285A1 Ver 8.4), and requires reprogramming of the Powertrain Control Module (PCM) for the 1999 and 2000 Grand Cherokees only (with calibration 99Cal20 (1999) or 00Cal17 (2000).** NOTE: THE 2001 GRAND CHEROKEE DOES NOT REQUIRE REPROGRAMMING OF THE PCM AS IT IS ALREADY AT THE CORRECT CALIBRATION LEVEL. NOTE: WHENEVER A PCM OR TCM IS REPLACED OR REPROGRAMMED, THE SOFTWARE OF THE PCM MUST BE VERIFIED AS HAVING THE LATEST REVISION LEVEL. MODELS: 2000 (AN) Dakota **2001** 2000 (DN) Durango **2001** 1999 (WJ) Grand Cherokee **2001 ** NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 4.7L ENGINE AND A 45RFE **OR 545RFE** TRANSMISSION. SYMPTOM/CONDITION: Some vehicles **may exhibit one or more of the following performance conditions **: 1. A harsh 2-3 upshift causing a powertrain clunk or shudder when accelerating. 2. **A harsh 4-5 upshift ('01 Grand Cherokee only).** 3. **A harsh 5-4 downshift ('01 Grand Cherokee only).** NOTE: THIS REVISION TO THE TCM SOFTWARE ADDRESSES THE ABOVE SHIFT QUALITY CONDITIONS FOR ALL VEHICLES AND, ADDS A FINAL GEAR RATIO TO THE **1999 AND 2000 MY** GRAND CHEROKEE TRANSMISSION ONLY. (2001 MY GRAND CHEROKEE ALREADY HAS THIS UPGRADE.) NOTE: TO MAINTAIN EMISSIONS COMPLIANCE, GRAND CHEROKEE VEHICLES THAT ARE EQUIPPED WITH A FEDERAL EMISSION SYSTEM (SALES CODE NAA) MUST HAVE THEIR PCM REPROGRAMMED. IF THE SOFTWARE LEVEL IS AT OR HIGHER THAN THOSE IN THE OVERVIEW ABOVE, OR IF THE GRAND CHEROKEE HAS A CALIFORNIA EMISSIONS SYSTEM (SALES CODE NAE), REPROGRAMMING IS NOT NECESSARY. DIAGNOSIS PROCEDURES: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRBIII(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 performing this repair. If no DTC's are present, and the above symptom has been experienced, perform the Repair Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > All Technical Service Bulletins for Powertrain Control Module: > 18-025-01 > Oct > 01 > A/T 45RFE/545RFE Harsh Upshifts/Downshifts > Page 273 Procedure. NOTE: **IF OTHER PERFORMANCE ISSUES REMAIN AFTER THE REPAIR PROCEDURE HAS BEEN PERFORMED THEY DO NOT RELATE TO THIS BULLETIN. REFER TO THE PROPER SERVICE OR DIAGNOSTIC PROCEDURES MANUAL(S) FOR FURTHER ASSISTANCE.** PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD **2093 OR HIGHER AND DRB III(R) VERSION 52.3 WILL BE IN THE DEALERSHIPS ON OCTOBER 15, 2001.)** REPAIR PROCEDURE: 1. Log onto the MDS2 (Mopar Diagnostic System). 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III(R), MDS2, AND VEHICLE ESTABLISH COMMUNICATION. 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. 3. Push the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) 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. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. 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, 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 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > All Technical Service Bulletins for Powertrain Control Module: > 18-025-01 > Oct > 01 > A/T 45RFE/545RFE Harsh Upshifts/Downshifts > Page 274 7. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 8. 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > All Other Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Powertrain Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > All Other Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 280 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > All Other Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 281 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > All Other Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 282 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 283 Powertrain Control Module: Specifications Powertrain Control Module Mounting Screws ................................................................................................................................. 3-5 Nm (30-40 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 284 Powertrain Control Module: Locations Powertrain Control Module Fig. 9 PCM Location The Powertrain Control Module (PCM) is located in the engine compartment. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 287 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 288 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 289 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 290 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 291 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 292 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 293 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 294 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 295 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 296 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 297 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 298 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 299 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 300 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 301 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 302 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 303 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 304 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 305 Powertrain Control Module: Connector Views Powertrain Control Module C1 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 306 Powertrain Control Module C2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 307 Powertrain Control Module C3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 308 Powertrain Control Module: Electrical Diagrams System Diagrams Refer to Powertrain Management/Diagrams/Electrical for wiring diagrams. See: Powertrain Management/Diagrams/Electrical Diagrams PCM Communication System Schematic Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 309 2001 Dodge JTEC System Federal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 310 2001 Dodge JTEC System California Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Page 311 Powertrain Control Module: Description and Operation Fig. 9 PCM Location POWERTRAIN CONTROL MODULE The Powertrain Control Module (PCM) is located in the engine compartment. The PCM is referred to as JTEC. The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. NOTE: PCM Inputs: A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - Auto shutdown (ASD) sense - Battery temperature - Battery voltage - Brake switch - CCD bus (+) circuits - CCD bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for DRB scan tool - Engine coolant temperature sensor - Fuel level - Generator (battery voltage) output - Ignition circuit sense (ignition switch in ON/OFF/crank/run position) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Page 312 - Intake manifold air temperature sensor - Leak detection pump (switch) sense (if equipped) - Manifold Absolute Pressure (MAP) sensor - Oil pressure - Output shaft speed sensor - Overdrive/override switch - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transmission governor pressure sensor - Transmission temperature sensor - Vehicle speed inputs from ABS or RWAL system NOTE: PCM Outputs: A/C clutch relay - Auto shutdown (ASD) relay - CCD bus (+A) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Generator lamp (if equipped) - Idle Air Control (IAC) motor Ignition coil - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through CCD circuits. - Overdrive indicator lamp (if equipped) - Radiator cooling fan - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through CCD circuits. - Transmission convertor clutch circuit - Transmission 3-4 shift solenoid - Transmission relay - Transmission temperature lamp (if equipped) - Transmission variable force solenoid MODES OF OPERATION As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. For example, the PCM must calculate different injector pulse width and ignition timing for idle than it does for wide open throttle (WOT). The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (O2S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (O2S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to-1 part fuel. By monitoring the exhaust oxygen content through the O2S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise - Acceleration Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Page 313 - Deceleration - Wide open throttle (WOT) - Ignition switch OFF The ignition switch ON, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. Ignition Switch (KEY-ON) Mode This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: The PCM pre-positions the idle air control (IAC) motor. - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the engine is operating or the starter motor is engaged. - The 02S sensor heater element is energized via the ASD relay. The 02S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. Engine Start-Up Mode This is an Open Loop mode. The following actions occur when the starter motor is engaged.The PCM receives inputs from: Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Starter motor relay - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector ON and OFF. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. Engine Warm-Up Mode This is an Open Loop mode. During engine warmup, the PCM receives inputs from: Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) - Park/neutral switch (gear indicator signal-auto.trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector ON and OFF. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the clutch relay. This is done if A/C has been selected by the vehicle operator and requested by the A/C thermostat. - When engine has reached operating temperature, the PCM will begin monitoring 02S sensor input. The system will then leave the warm-up mode and go into closed loop operation. Idle Mode When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: Air conditioning select signal (if equipped) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Page 314 - Air conditioning request signal (if equipped) - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector ON and OFF. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio by varying injector pulse width.It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. Cruise Mode When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen (O2S) sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector ON and OFF. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control ('AC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil ON and OFF. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. Acceleration Mode This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. Deceleration Mode When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed sensor If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Page 315 The PCM adjusts ignition timing by turning the ground path to the coil ON and OFF. Wide Open Throttle Mode This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) During wide open throttle conditions, the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector ON and OFF. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil ON and OFF. ignition switch OFF Mode When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. 5 VOLT SUPPLIES Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. Primary 5-volt supply: supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5-volt supply: supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (if equipped with an RE automatic transmission). IGNITION CIRCUIT SENSE This circuit ties the ignition switch to the Power- train Control Module (PCM). The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Voltage ON the ignition input can be as low as 6 volts and the PCM will still function. Voltage is supplied to this circuit to power the PCM's 8-volt regulator and to allow the PCM to perform fuel, ignition and emissions control functions. POWER GROUND The Powertrain Control Module (PCM) has 2 main grounds. Both of these grounds are referred to as power grounds. All of the high-current, noisy, electrical devices are connected to these grounds as well as all of the sensor returns. The sensor return comes into the sensor return circuit, passes through noise suppression, and is then connected to the power ground. The power ground is used to control ground circuits for the following PCM loads: Generator field winding - Fuel injectors - Ignition coil(s) - Certain relays/solenoids - Certain sensors SENSOR RETURN The Sensor Return circuits are internal to the Powertrain Control Module (PCM). Sensor Return provides a low-noise ground reference for all engine control system sensors. Refer to Power Grounds for more information. SIGNAL GROUND Signal ground provides a low noise ground to the data link connector. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Page 316 Powertrain Control Module: Service and Repair REMOVAL USE THE DRB SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. Fig. 10 PCM Location And Mounting The PCM is located in the engine compartment. To avoid possible voltage spike damage to the PCM, ignition key must be OFF and negative battery cable must be disconnected before unplugging PCM connectors. 1. Disconnect negative battery cable at battery. 2. Remove cover over electrical connectors. Cover snaps onto PCM. 3. Carefully unplug the three 32-way connectors from PCM. 4. Remove three PCM mounting bolts and remove PCM from vehicle. INSTALLATION USE THE DRB SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. 1. Install PCM and mounting bolts to vehicle. 2. Tighten bolts to 3-5 Nm (30-40 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 cover over electrical connectors. Cover snaps onto PCM. 6. Install battery cable. 7. Use the DRB scan tool to reprogram new PCM with vehicles original Identification Number (VIN) and original vehicle mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Auto Shut Down (ASD) Relay: Locations Power Distribution Center Automatic Shut Down Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 320 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 321 Auto Shut Down (ASD) Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 322 Automatic Shut Down Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 323 Auto Shut Down (ASD) Relay: Description and Operation AUTO SHUT DOWN RELAY PCM Output The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit ON and OFF. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. ASD Sense - PCM Input A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 324 Auto Shut Down (ASD) Relay: Testing and Inspection Fig. 1 ASD And Fuel Pump Relay Terminals - Type 1 Fig. 2 ASD And Fuel Pump Terminals - Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 325 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 326 Auto Shut Down (ASD) Relay: Service and Repair Fig. 3 Power Distribution Center (PDC) Location REMOVAL The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations Oxygen Sensor Relay: Locations Power Distribution Center Oxygen Sensor Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 330 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 331 Oxygen Sensor Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 332 Oxygen Sensor Downstream Heater Relay (California) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 333 Oxygen Sensor Relay: Description and Operation OXYGEN HEATER RELAY The oxygen (O2) sensor heater relay is located in the Powertrain Distribution Center (PDC). Refer to Oxygen Sensor for oxygen sensor relay information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 334 Oxygen Sensor Relay: Service and Repair Fig. 21 Power Distribution Center (PDC) REMOVAL The oxygen sensor heater relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The oxygen sensor heater relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Fuel Pump Relay: Locations Power Distribution Center Fuel Pump Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 339 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 340 Fuel Pump Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 341 Fuel Pump Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 342 Fuel Pump Relay: Description and Operation The 5-pin, 12-volt, fuel pump relay is located in the Power Distribution Center (PDC). Refer to the label on the PDC cover for relay location. The Powertrain Control Module (PCM) energizes the electric fuel pump through the fuel pump relay. The fuel pump relay is energized by first applying battery voltage to it when the ignition key is turned ON, and then applying a ground signal to the relay from the PCM. Whenever the ignition key is turned ON, the electric fuel pump will operate. But, the PCM will shutdown the ground circuit to the fuel pump relay in approximately 1-3 seconds unless the engine is operating or the starter motor is engaged. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 343 Fuel Pump Relay: Testing and Inspection Fig. 1 ASD And Fuel Pump Relay Terminals - Type 1 Fig. 2 ASD And Fuel Pump Terminals - Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, (Fig. 1) or (Fig. 2). - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 344 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 345 Fuel Pump Relay: Service and Repair Fig. 21 Power Distribution Center (PDC) REMOVAL The fuel pump relay is located in the Power Distribution Center (PDC) (Fig. 21). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The fuel pump relay is located in the Power Distribution Center (PDC) (Fig. 21). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Auto Shut Down (ASD) Relay: Locations Power Distribution Center Automatic Shut Down Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 349 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 350 Auto Shut Down (ASD) Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 351 Automatic Shut Down Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 352 Auto Shut Down (ASD) Relay: Description and Operation AUTO SHUT DOWN RELAY PCM Output The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit ON and OFF. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. ASD Sense - PCM Input A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 353 Auto Shut Down (ASD) Relay: Testing and Inspection Fig. 1 ASD And Fuel Pump Relay Terminals - Type 1 Fig. 2 ASD And Fuel Pump Terminals - Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 354 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 355 Auto Shut Down (ASD) Relay: Service and Repair Fig. 3 Power Distribution Center (PDC) Location REMOVAL The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Module Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 360 Airbag Control Module Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 361 Air Bag Control Module: Service Precautions WARNING: - DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONERS, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAGS. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 362 Air Bag Control Module: Description and Operation The Airbag Control Module (ACM) is secured with screws to a mount welded onto the top of the floor panel transmission tunnel behind the instrument panel center support bracket in the passenger compartment of the vehicle. The ACM contains an electronic microprocessor, an electronic impact sensor, an electromechanical safing sensor, and an energy storage capacitor. The ACM is connected to the vehicle electrical system through a take out and connector of the instrument panel wire harness. The ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. The microprocessor in the ACM contains the airbag system logic circuits, and it monitors and controls all of the airbag system components. The ACM also uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the DRB III scan tool using the Programmable Communications Interface (PCI) data bus network. This method of communication is used for control of the airbag indicator in the ElectroMechanical Instrument Cluster (EMIC) and for airbag system diagnosis and testing through the 16-way data link connector located on the lower left edge of the instrument panel. (Refer to INSTRUMENT CLUSTER/AIRBAG INDICATOR - OPERATION). The ACM microprocessor continuously monitors all of the airbag system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sets an active Diagnostic Trouble Code (DTC) and sends messages to the EMIC over the PCI data bus to turn ON the airbag indicator. If the airbag system fault is still present when the ignition switch is turned to the OFF position, the DTC is stored in memory by the ACM. However, if a fault does not recur for a number of ignition cycles, the ACM will automatically erase the stored DTC. The ACM receives battery current through two circuits, on a fused ignition switch output (run) circuit through a fuse in the Junction Block (JB), and on a fused ignition switch output (run-start) circuit through a second fuse in the JB. The ACM is grounded through a ground circuit and take out of the instrument panel wire harness. This take out has a single eyelet terminal connector secured by a ground screw to the left side of the floor panel transmission tunnel near the ACM in the passenger compartment. Therefore, the ACM is operational whenever the ignition switch is in the Start or ON positions. The ACM also contains an energy-storage capacitor. When the ignition switch is in the Start or ON positions, this capacitor is continually being charged with enough electrical energy to deploy the airbags for up to one second following a battery disconnect or failure. The purpose of the capacitor is to provide backup airbag system protection in case there is a loss of battery current supply to the ACM during an impact. The capacitor is only serviced as a unit with the ACM. Two sensors are contained within the ACM, an electronic impact sensor and a safing sensor. The electronic impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. A pre-programmed decision algorithm in the ACM microprocessor determines when the deceleration rate as signaled by the impact sensor 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 airbags and the seat belt tensioners. The safing sensor is an electromechanical sensor within the ACM that is connected in series between the ACM microprocessor deployment circuit and the airbags/seat belt tensioners. The safing sensor is a normally open switch that is used to verify or confirm the need for an airbag deployment by detecting impact energy of a lesser magnitude than that of the electronic impact sensor, and must be closed in order for the airbags/seat belt tensioners to deploy. The impact sensor and safing sensor are calibrated for the specific vehicle, and are only serviced as a unit with the ACM. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 363 Air Bag Control Module: Service and Repair REMOVAL WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONERS, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAGS. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. 1. Disconnect and isolate the battery negative cable. If either of the airbags has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. From the right side of the floor panel transmission tunnel, remove the screw that secures the floor duct adapter to the bottom of the heater-air conditioner housing. 3. Remove the floor duct adapter from the bottom of the heater-air conditioner housing. 4. Pull the carpet on the right and left sides of the floor panel transmission tunnel rearward far enough to access the Airbag Control Module (ACM). Fig. 5 Airbag Control Module 5. Remove the two screws that secure the ACM to the right side of the mounting bracket that is welded onto the floor panel transmission tunnel. 6. Remove the two screws that secure the ACM to the left side of the mounting bracket that is welded onto the floor panel transmission tunnel. 7. Lift the ACM upward from the mounting bracket far enough to disengage the locator pins on the ACM housing from the locator holes in the mounting bracket, then pull the ACM out from under the instrument panel far enough to access the wire harness connector. 8. Disconnect the instrument panel wire harness connector for the ACM from the ACM connector receptacle. To disconnect the instrument panel wire harness connector for the ACM: a. Slide the red Connector Position Assurance (CPA) lock on the top of the connector toward the right side of the vehicle. b. Depress the latch tab on the upper surface of the connector, and pull the connector straight away from the ACM connector receptacle. 9. Remove the ACM from beneath the instrument panel. INSTALLATION WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONERS, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 364 DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAGS. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. 1. Position the Airbag Control Module (ACM) beneath the instrument panel. 2. Reconnect the instrument panel wire harness connector for the ACM to the ACM connector receptacle. Be certain that the connector latch and the red Connector Position Assurance (CPA) lock are fully engaged. 3. Carefully position the ACM to the mounting bracket that is welded onto the floor panel transmission tunnel. When the ACM is correctly positioned, the locator pins on the ACM housing will be engaged in the locator holes in the mounting bracket, and the arrow on the ACM label will be pointed forward in the vehicle. 4. Install and tighten the two screws that secure the ACM to the right side of the mounting bracket that is welded onto the floor panel transmission tunnel. Tighten the screws to 12 Nm (105 in. lbs.). 5. Install and tighten the two screws that secure the ACM to the left side of the mounting bracket that is welded onto the floor panel transmission tunnel. Tighten the screws to 12 Nm (105 in. lbs.). 6. Restore the carpet on the right and left sides of the floor panel transmission tunnel to its proper position beneath the instrument panel. 7. From the right side of the floor panel transmission tunnel, position the floor duct adapter onto the bottom of the heater-air conditioner housing. 8. Install and tighten the screw that secures the floor duct adapter to the bottom of the heater-air conditioner housing. Tighten the screw to 2 Nm (17 in. lbs.). 9. Do not reconnect the battery negative cable at this time. The airbag system verification test procedure should be performed following service of any airbag system component. (Refer to RESTRAINTS - STANDARD PROCEDURE VERIFICATION TEST). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Power Distribution Center Starter Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 369 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 370 Starter Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 371 Engine Starter Motor Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 372 Starter Relay: Description and Operation The starter relay is an electromechanical device that switches battery current to the pull-in coil of the starter solenoid when ignition switch is turned to Start position. The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. See PDC cover for relay identification and location. The starter relay is a International Standards Organization (ISO) relay. Relays conforming to ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The starter relay cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When electromagnetic coil is energized, it draws the movable contact away from normally closed fixed contact, and holds it against the other (normally open) fixed contact. When electromagnetic coil is de-energized, spring pressure returns movable contact to normally closed position. The resistor or diode is connected in parallel with electromagnetic coil within relay, and helps to dissipate voltage spikes produced when coil is de-energized. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 373 Starter Relay: Testing and Inspection Fig. 11 Starter Relay The starter relay (Fig. 11) is located in Power Distribution Center (PDC). Refer to PDC cover for relay identification and location. 1. Remove starter relay from PDC. 2. A relay in de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace faulty relay. 4. Connect 12V battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, perform Relay Circuit Test that follows. If not OK, replace faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair open circuit to fuse in PDC as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to common feed terminal (30) in the energized position. This terminal supplies battery voltage to starter solenoid field coils. There should be continuity between cavity for relay terminal 87 and starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair open circuit to starter solenoid as required. 4. The coil battery terminal (86) is connected to electromagnet in relay. It is energized when ignition switch is held in Start position. On vehicles with manual transmission, clutch pedal must be fully depressed for this test. Check for battery voltage at cavity for relay terminal 86 with ignition switch in Start position, and no voltage when ignition switch is released to ON position. If OK, go to Step 5. If not OK with automatic transmission, check for open or short circuit to ignition switch and repair, if required. If circuit to ignition switch is OK, refer to Ignition Switch and Key Lock Cylinder. If not OK with a manual transmission, check circuit between relay and clutch pedal position switch for open or a short. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. On vehicles with manual transmission, it is grounded at all times. On vehicles with automatic transmission, it is grounded through park/neutral position switch only when gearshift selector lever is in Park or Neutral positions. Check for continuity to ground at cavity for relay terminal 85. If not OK with manual transmission, repair circuit to ground as required. If not OK with automatic transmission, check for pen or short circuit to park/neutral position switch and repair, if required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 374 Starter Relay: Service and Repair REMOVAL 1. Disconnect and isolate negative battery cable. Fig. 12 Power Distribution Center 2. Remove cover from Power Distribution Center (PDC) (Fig. 12). 3. See fuse and relay layout label affixed to underside of PDC cover for starter relay identification and location. 4. Remove starter relay from PDC. INSTALLATION 1. See fuse and relay layout label affixed to underside of PDC cover for proper starter relay location. 2. Position starter relay in proper receptacle in PDC. 3. Align starter relay terminals with terminal cavities in PDC receptacle. 4. Push down firmly on starter relay until terminals are fully seated in terminal cavities in PDC receptacle. 5. Install cover onto PDC. 6. Reconnect negative battery cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > Customer Interest for Transmission Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts Transmission Control Module: Customer Interest A/T - 45RFE/545RFE Harsh Upshifts/Downshifts NUMBER: 18-025-01 GROUP: Vehicle Performance DATE: October 15, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-09-00, DATED SEPTEMBER 15, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. **ASTERISKS** HAVE BEEN USED TO HIGHLIGHT CHANGES. THIS BULLETIN ADDS A MODEL YEAR AND REQUIRES A REPROGRAMMING OF THE 1999 AND 2000 GRAND CHEROKEE POWERTRAIN CONTROL MODULE (PCM). SUBJECT: 45RFE **and 545RFE Shift** Quality Enhancements for the** 2-3, 4-5, and 5-4** Shifts OVERVIEW: This bulletin involves selectively erasing and reprogramming the **Transmission Control Module (TCM) with new software: '99-'01 WJ (PN 05019701AC Ver 9.3), '00 AN/DN (PN 05018454AB Ver 9.1), or '01 AN/DN (PN 56028285A1 Ver 8.4), and requires reprogramming of the Powertrain Control Module (PCM) for the 1999 and 2000 Grand Cherokees only (with calibration 99Cal20 (1999) or 00Cal17 (2000).** NOTE: THE 2001 GRAND CHEROKEE DOES NOT REQUIRE REPROGRAMMING OF THE PCM AS IT IS ALREADY AT THE CORRECT CALIBRATION LEVEL. NOTE: WHENEVER A PCM OR TCM IS REPLACED OR REPROGRAMMED, THE SOFTWARE OF THE PCM MUST BE VERIFIED AS HAVING THE LATEST REVISION LEVEL. MODELS: 2000 (AN) Dakota **2001** 2000 (DN) Durango **2001** 1999 (WJ) Grand Cherokee **2001 ** NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 4.7L ENGINE AND A 45RFE **OR 545RFE** TRANSMISSION. SYMPTOM/CONDITION: Some vehicles **may exhibit one or more of the following performance conditions **: 1. A harsh 2-3 upshift causing a powertrain clunk or shudder when accelerating. 2. **A harsh 4-5 upshift ('01 Grand Cherokee only).** 3. **A harsh 5-4 downshift ('01 Grand Cherokee only).** NOTE: THIS REVISION TO THE TCM SOFTWARE ADDRESSES THE ABOVE SHIFT QUALITY CONDITIONS FOR ALL VEHICLES AND, ADDS A FINAL GEAR RATIO TO THE **1999 AND 2000 MY** GRAND CHEROKEE TRANSMISSION ONLY. (2001 MY GRAND CHEROKEE ALREADY HAS THIS UPGRADE.) NOTE: TO MAINTAIN EMISSIONS COMPLIANCE, GRAND CHEROKEE VEHICLES THAT ARE EQUIPPED WITH A FEDERAL EMISSION SYSTEM (SALES CODE NAA) MUST HAVE THEIR PCM REPROGRAMMED. IF THE SOFTWARE LEVEL IS AT OR HIGHER THAN THOSE IN THE OVERVIEW ABOVE, OR IF THE GRAND CHEROKEE HAS A CALIFORNIA EMISSIONS SYSTEM (SALES CODE NAE), REPROGRAMMING IS NOT NECESSARY. DIAGNOSIS PROCEDURES: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRBIII(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 performing this repair. If no DTC's are present, and the above symptom has been experienced, perform the Repair Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > Customer Interest for Transmission Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts > Page 385 Procedure. NOTE: **IF OTHER PERFORMANCE ISSUES REMAIN AFTER THE REPAIR PROCEDURE HAS BEEN PERFORMED THEY DO NOT RELATE TO THIS BULLETIN. REFER TO THE PROPER SERVICE OR DIAGNOSTIC PROCEDURES MANUAL(S) FOR FURTHER ASSISTANCE.** PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD **2093 OR HIGHER AND DRB III(R) VERSION 52.3 WILL BE IN THE DEALERSHIPS ON OCTOBER 15, 2001.)** REPAIR PROCEDURE: 1. Log onto the MDS2 (Mopar Diagnostic System). 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III(R), MDS2, AND VEHICLE ESTABLISH COMMUNICATION. 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. 3. Push the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) 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. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. 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, 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 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > Customer Interest for Transmission Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts > Page 386 7. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 8. 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts Transmission Control Module: All Technical Service Bulletins A/T - 45RFE/545RFE Harsh Upshifts/Downshifts NUMBER: 18-025-01 GROUP: Vehicle Performance DATE: October 15, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-09-00, DATED SEPTEMBER 15, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. **ASTERISKS** HAVE BEEN USED TO HIGHLIGHT CHANGES. THIS BULLETIN ADDS A MODEL YEAR AND REQUIRES A REPROGRAMMING OF THE 1999 AND 2000 GRAND CHEROKEE POWERTRAIN CONTROL MODULE (PCM). SUBJECT: 45RFE **and 545RFE Shift** Quality Enhancements for the** 2-3, 4-5, and 5-4** Shifts OVERVIEW: This bulletin involves selectively erasing and reprogramming the **Transmission Control Module (TCM) with new software: '99-'01 WJ (PN 05019701AC Ver 9.3), '00 AN/DN (PN 05018454AB Ver 9.1), or '01 AN/DN (PN 56028285A1 Ver 8.4), and requires reprogramming of the Powertrain Control Module (PCM) for the 1999 and 2000 Grand Cherokees only (with calibration 99Cal20 (1999) or 00Cal17 (2000).** NOTE: THE 2001 GRAND CHEROKEE DOES NOT REQUIRE REPROGRAMMING OF THE PCM AS IT IS ALREADY AT THE CORRECT CALIBRATION LEVEL. NOTE: WHENEVER A PCM OR TCM IS REPLACED OR REPROGRAMMED, THE SOFTWARE OF THE PCM MUST BE VERIFIED AS HAVING THE LATEST REVISION LEVEL. MODELS: 2000 (AN) Dakota **2001** 2000 (DN) Durango **2001** 1999 (WJ) Grand Cherokee **2001 ** NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 4.7L ENGINE AND A 45RFE **OR 545RFE** TRANSMISSION. SYMPTOM/CONDITION: Some vehicles **may exhibit one or more of the following performance conditions **: 1. A harsh 2-3 upshift causing a powertrain clunk or shudder when accelerating. 2. **A harsh 4-5 upshift ('01 Grand Cherokee only).** 3. **A harsh 5-4 downshift ('01 Grand Cherokee only).** NOTE: THIS REVISION TO THE TCM SOFTWARE ADDRESSES THE ABOVE SHIFT QUALITY CONDITIONS FOR ALL VEHICLES AND, ADDS A FINAL GEAR RATIO TO THE **1999 AND 2000 MY** GRAND CHEROKEE TRANSMISSION ONLY. (2001 MY GRAND CHEROKEE ALREADY HAS THIS UPGRADE.) NOTE: TO MAINTAIN EMISSIONS COMPLIANCE, GRAND CHEROKEE VEHICLES THAT ARE EQUIPPED WITH A FEDERAL EMISSION SYSTEM (SALES CODE NAA) MUST HAVE THEIR PCM REPROGRAMMED. IF THE SOFTWARE LEVEL IS AT OR HIGHER THAN THOSE IN THE OVERVIEW ABOVE, OR IF THE GRAND CHEROKEE HAS A CALIFORNIA EMISSIONS SYSTEM (SALES CODE NAE), REPROGRAMMING IS NOT NECESSARY. DIAGNOSIS PROCEDURES: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRBIII(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 performing this repair. If no DTC's are present, and the above symptom has been experienced, perform the Repair Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts > Page 392 Procedure. NOTE: **IF OTHER PERFORMANCE ISSUES REMAIN AFTER THE REPAIR PROCEDURE HAS BEEN PERFORMED THEY DO NOT RELATE TO THIS BULLETIN. REFER TO THE PROPER SERVICE OR DIAGNOSTIC PROCEDURES MANUAL(S) FOR FURTHER ASSISTANCE.** PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD **2093 OR HIGHER AND DRB III(R) VERSION 52.3 WILL BE IN THE DEALERSHIPS ON OCTOBER 15, 2001.)** REPAIR PROCEDURE: 1. Log onto the MDS2 (Mopar Diagnostic System). 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III(R), MDS2, AND VEHICLE ESTABLISH COMMUNICATION. 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. 3. Push the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) 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. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. 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, 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 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts > Page 393 7. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 8. 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > Page 394 Transmission Control Module: Locations Fig. 13 Transmission Control Module Location The Transmission Control Module (TCM) is located in the engine compartment on the right (passenger) side and is mounted to the radiator core support. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions Transmission Control Module: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 397 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 398 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 399 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 400 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 401 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 402 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 403 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 404 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 405 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 406 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 407 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 408 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 409 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 410 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 411 Transmission Control Module: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 412 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 413 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 414 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 415 Transmission Control Module: Connector Views Transmission Control Module Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 416 Transmission Control Module Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 417 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 418 Transmission Control Module: Description and Operation Fig. 13 Transmission Control Module Location The Transmission Control Module (TCM) is located in the engine compartment on the right (passenger) side and is mounted to the radiator core support (Fig. 13). The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hardwired to, and used specifically by the TCM. Indirect inputs originate from other components/modules, and are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - DRB Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 419 - Transmission Temperature (to PCM) - PRNDL Position (to BCM) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with DRB scan tool) NOTE: If the TCM has been replaced, the "Quick Learn Procedure" must be performed. (Refer to ELECTRONIC CONTROL MODULES/ TRANSMISSION CONTROL MODULE - STANDARD PROCEDURE) Battery Feed A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain adaptive learn values in the TCM's RAM (Random Access Memory). When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. Clutch Volume Indexes (CVI) An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. Fig. 14 Example Of CVI Calculation By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur (Fig. 14). Gear ratios can be determined by using the DRB Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 420 The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Clutch Volumes Certain mechanical problems within the input clutch assembly (broken return springs, out of position snap rings, excessive clutch pack clearance, improper assembly, etc.) can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following chart identifies the appropriate clutch volumes and when they are monitored/updated: Shift Schedules As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 421 Driving Conditions As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 422 Transmission Control Module: Service and Repair STANDARD PROCEDURES The quick learn procedure requires the use of the DRB scan tool. This program allows the electronic transmission system to recalibrate itself. This will provide the proper transmission operation. The quick learn procedure should be performed if any of the following procedures are performed: Transmission Assembly Replacement - Transmission Control Module Replacement - Solenoid Pack Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees. - The shift lever position must stay in PARK until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the DRB III indicates the procedure is complete - The calculated oil temperature must be above 60 ° and below 200 ° Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Transmission Control System Relay: Locations Power Distribution Center Transmission Control Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 426 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 427 Transmission Control System Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 428 Transmission Control Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 429 Transmission Control System Relay: Description and Operation DESCRIPTION The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. OPERATION When the relay is "off," no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Recalls for Control Module: > NHTSA01V077000 > Mar > 01 > Recall 01V077000: Transfer Case Control Module Problem Control Module: Recalls Recall 01V077000: Transfer Case Control Module Problem Vehicle Description: Light duty trucks and sport utility vehicles equipped with 4-wheel drive. The electric shift transfer case may not fully engage into gear when the operator moves the transfer case selector switch. This could cause the transfer case to end up in the neutral position unexpectedly and allow the vehicle to roll away if the parking brake is not applied. Dealers will reprogram the transfer case control module. Owner notification began April 9, 2001. 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 DaimlerChrysler at 1-800-853-1403. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > NHTSA01V077000 > Mar > 01 > Recall 01V077000: Transfer Case Control Module Problem Control Module: All Technical Service Bulletins Recall 01V077000: Transfer Case Control Module Problem Vehicle Description: Light duty trucks and sport utility vehicles equipped with 4-wheel drive. The electric shift transfer case may not fully engage into gear when the operator moves the transfer case selector switch. This could cause the transfer case to end up in the neutral position unexpectedly and allow the vehicle to roll away if the parking brake is not applied. Dealers will reprogram the transfer case control module. Owner notification began April 9, 2001. 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 DaimlerChrysler at 1-800-853-1403. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Rear Window Defogger Relay <--> [Heated Glass Element Relay] > Component Information > Locations Rear Window Defogger Relay: Locations Power Distribution Center Rear Defogger Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Rear Window Defogger Relay <--> [Heated Glass Element Relay] > Component Information > Locations > Page 448 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Rear Window Defogger Relay <--> [Heated Glass Element Relay] > Component Information > Locations > Page 449 Rear Window Defogger Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Rear Window Defogger Relay <--> [Heated Glass Element Relay] > Component Information > Locations > Page 450 Rear Window Defogger Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Description and Operation Wiper Control Module: Description and Operation FRONT WIPER MODULE The wiper module is secured with screws through four rubber grommet-type insulators to the cowl plenum panel and concealed within the cowl plenum area beneath the cowl plenum cover/grille panel. The ends of the wiper pivot shafts that protrude through dedicated openings in the cowl plenum cover/grille panel to drive the wiper arms and blades are the only visible components of the wiper module. The wiper module consists of the following major components: Bracket - The wiper module bracket consists of a long tubular steel main member that has a stamped pivot bracket formation near each end where the two wiper pivots are secured. A stamped steel mounting plate for the wiper motor is secured with welds near the center of the main member. - Crank Arm - The wiper motor crank arm is a stamped steel unit that has a slotted hole on the driven end that is secured to the wiper motor output shaft with a nut, and has a ball stud secured to the drive end. - Linkage - The two wiper linkage members are each constructed of stamped steel. A driver side drive link with a plastic socket-type bushing in the left end, and a plastic sleeve-type bushing in the right end. Socket bushing is snap-fit over the pivot ball stud on the left pivot, while the sleeve bushing is fit over the longer wiper motor crank arm pivot stud. The passenger side drive link has a plastic socket-type bushing on each end. One end of this drive link is snap-fit over the pivot ball stud on the right pivot, while the other end is snap-fit over the exposed end of the longer ball stud on the wiper motor crank arm. - Motor - The wiper motor is secured with three screws to the motor mounting plate near the center of the wiper module bracket. The wiper motor output shaft passes through a hole in the module bracket, where a nut secures the wiper motor crank arm to the motor output shaft. The two-speed permanent magnet wiper motor features an integral transmission, an internal park switch, and an internal Positive Temperature Coefficient (PTC) circuit breaker. - Pivots - The two wiper pivots are secured to the ends of the wiper module bracket. The crank arms that extend from the bottom of the pivot shafts each have a ball stud on their end. The upper end of each pivot shaft where the wiper arms will be fastened each has an externally serrated drum secured to it. The wiper module cannot be adjusted or repaired. If any component of the module is faulty or damaged, the entire wiper module unit must be replaced. The wiper module operation is controlled by the vehicle operator through battery current inputs received by the wiper motor from the multi-function switch on the steering column. The wiper motor speed is controlled by current flow to either the low speed or the high speed set of brushes. The park switch is a single pole, single throw, momentary switch within the wiper motor that is mechanically actuated by the wiper motor transmission components. The park switch alternately closes the wiper park switch sense circuit to ground or to battery current, depending upon the position of the wipers on the glass. This feature allows the motor to complete its current wipe cycle after the wiper system has been turned OFF, and to park the wiper blades in the lowest portion of the wipe pattern. The automatic resetting circuit breaker protects the motor from overloads. The wiper motor crank arm, the two wiper linkage members, and the two wiper pivots mechanically convert the rotary output of the wiper motor to the back and forth wiping motion of the wiper arms and blades on the glass. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Description and Operation > Page 455 Wiper Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the front wiper arms from the wiper pivots. (Refer to FRONT WIPER ARMS - REMOVAL). 3. Remove the cowl plenum cover/grille panel from the cowl plenum. Fig.11 Wiper Module Removal/Install 4. Remove the four screws that secure the front wiper module bracket to the cowl plenum panel and the dash panel. 5. Reach into the cowl plenum to move the front wiper module far enough to access the wiper module electrical connections. 6. Disconnect the headlamp and dash wire harness connector for the front wiper motor from the wiper motor pigtail wire connector. 7. Disconnect the headlamp and dash wire harness ground connector from the front wiper motor ground terminal. 8. Remove the front wiper module from the cowl plenum as a unit. INSTALLATION 1. Position the front wiper module into the cowl plenum as a unit. 2. Reconnect the headlamp and dash wire harness ground connector to the front wiper motor ground terminal. 3. Reconnect the headlamp and dash wire harness connector for the front wiper motor to the wiper motor pigtail wire connector. 4. Reach into the cowl plenum to align the front wiper module mounting bracket with the locations for the mounting screws. 5. Install and tighten the four screws that secure the front wiper module bracket to the cowl plenum panel and the dash panel. Tighten the screws to 8 Nm (72 in. lbs.). 6. Reinstall the cowl plenum cover/grille panel over the top of the cowl plenum. 7. Reinstall the front wiper arms onto the wiper pivots. (Refer to FRONT WIPER ARMS - INSTALLATION). 8. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Power Distribution Center Wiper Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 459 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 460 Wiper Relay: Diagrams Front Wiper Motor Relay Rear Wiper Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 461 Wiper Relay: Description and Operation FRONT WIPER RELAY The front wiper relay (or intermittent wipe relay) is located in the Power Distribution Center (PDC) near the battery in the engine compartment. See the fuse and relay layout label affixed to the inside surface of the PDC cover for front wiper relay identification and location. The front wiper relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The relay is contained within a small, rectangular, molded plastic housing. The relay is connected to all of the required inputs and outputs through its PDC receptacle by five male spade-type terminals that extend from the bottom of the relay base. The ISO designation for each terminal is molded into the base adjacent to the terminal. The ISO terminal designations are as follows: 30 (Common Feed) - This terminal is connected to the movable contact point of the relay. - 85 (Coil Ground) - This terminal is connected to the ground feed side of the relay control coil. - 86 (Coil Battery) - This terminal is connected to the battery feed side of the relay control coil. - 87 (Normally Open) - This terminal is connected to the normally open fixed contact point of the relay. - 87A (Normally Closed) - This terminal is connected to the normally closed fixed contact point of the relay. The front wiper relay cannot be adjusted or repaired. If the relay is damaged or faulty, it must be replaced. The front wiper relay (or intermittent wipe relay) is an electromechanical switch that uses a low current input from the Central Timer Module ( CTM) to control a high current output to the low speed brush of the front wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor or diode is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The front wiper relay terminals are connected to the vehicle electrical system through a connector receptacle in the Power Distribution Center (PDC). The inputs and outputs of the front wiper relay include: The common feed terminal (30) is connected to the front wiper motor low speed brush through the wiper control circuitry of the multi-function switch on the steering column. When the front wiper relay is de-energized, the common feed terminal is connected to the front wiper park switch output through the CTM on the front wiper park switch sense circuit. The front wiper park switch output may be battery current (wipers are not parked), or ground (wipers are parked). When the front wiper relay is energized, the common feed terminal of the relay is connected to battery current from a fuse in the Junction Block (JB) through a fused ignition switch output (run-acc) circuit. - The coil ground terminal (85) is connected to the relay control output of the CTM through the wiper relay control circuit. The CTM controls the ground path for this circuit internally to energize or de-energize the front wiper relay based upon its programming, inputs from the front wiper and washer control circuitry of the multi-function switch, and inputs from the front wiper motor park switch. The coil battery terminal (86) is connected to battery current from a fuse in the Junction Block (JB) through a fused ignition switch output (run-acc) circuit whenever the ignition switch is in the ON or Accessory positions. - The normally open terminal (87) is connected to battery current from a fuse in the Junction Block (JB) through a fused ignition switch output (run-acc) circuit whenever the front wiper relay control coil is energized by the CTM. This circuit provides fused ignition switch output (run-acc) current to the front wiper motor low speed brush only when the front wiper relay control coil is energized. - The normally closed terminal (87A) is connected to the output of the front wiper motor park switch through the CTM on the front wiper park switch sense circuit. This circuit provides battery current (wipers are not parked) or ground (wipers are parked) to the front wiper motor low speed brush whenever the front wiper relay control coil is de-energized and the OFF position of the front wiper control circuitry within the multi-function switch is selected. The front wiper relay can be diagnosed using conventional diagnostic tools and methods. REAR WIPER RELAY The rear wiper relay is located in the Power Distribution Center (PDC) near the battery in the engine compartment. See the fuse and relay layout label affixed to the inside surface of the PDC cover for rear wiper relay identification and location. The rear wiper relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The relay is contained within a small, rectangular, molded plastic housing. The relay is connected to all of the required inputs and outputs through its PDC receptacle by five male spade-type terminals that extend from the bottom of the relay base. The ISO designation for each terminal is molded into the base adjacent to the terminal. The ISO terminal designations are as follows: 30 (Common Feed) - This terminal is connected to the movable contact point of the relay. - 85 (Coil Ground) - This terminal is connected to the ground feed side of the relay control coil. - 86 (Coil Battery) - This terminal is connected to the battery feed side of the relay control coil. - 87 (Normally Open) - This terminal is connected to the normally open fixed contact point of the relay. - 87A (Normally Closed) - This terminal is connected to the normally closed fixed contact point of the relay. The rear wiper relay cannot be adjusted or repaired. If the relay is damaged or faulty, it must be replaced. The rear wiper relay is an electromechanical switch that uses a low current input from the Central Timer Module (CTM) to control a high current output to the rear wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 462 contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor or diode is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The rear wiper relay terminals are connected to the vehicle electrical system through a connector receptacle in the Power Distribution Center (PDC). The inputs and outputs of the rear wiper relay include: - The common feed terminal (30) is connected to the rear wiper motor through the rear wiper motor control circuit to the rear wiper motor. When the rear wiper relay is de-energized, the common feed terminal is connected to ground through a take out and eyelet terminal connector of the headlamp and dash wire harness that is secured by a nut to a ground stud located on the left front fender inner shield in the engine compartment near the battery. When the rear wiper relay is energized, the common feed terminal of the relay is connected to battery current from a fuse in the Power Distribution Center (PDC) through a fused B(+) circuit. - The coil ground terminal (85) is connected to the relay control output of the CTM through the rear wiper relay control circuit. The CTM controls the ground path for this circuit internally to energize or de-energize the rear wiper relay based upon its programming, electronic wiper and washer switch state message inputs from the heater-air conditioner control, and a hard wired input from the rear wiper motor park switch. - The coil battery terminal (86) is connected to battery current from a fuse in the PDC through a fused B(+) circuit at all times. - The normally open terminal (87) is connected to battery current from a fuse in the PDC through a fused B(+) circuit at all times. - The normally closed terminal (87A) is connected to ground through a take out and eyelet terminal connector of the headlamp and dash wire harness that is secured by a nut to a ground stud located on the left front fender inner shield in the engine compartment near the battery. The rear wiper relay can be diagnosed using conventional diagnostic tools and methods. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Front Wiper Relay Test Wiper Relay: Testing and Inspection Front Wiper Relay Test Fig. 9 Front Wiper Relay The front wiper relay (or intermittent wipe relay) is located in the Power Distribution Center (PDC) in the engine compartment. See the fuse and relay layout label affixed to the inside surface of the PDC cover for front wiper relay identification and location. 1. Remove the front wiper relay from the PDC. (Refer to FRONT WIPER RELAY - REMOVAL). 2. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 4. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, test the relay input and output circuits. Refer to RELAY CIRCUIT TEST . If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to the multi-function switch. There should be continuity between the receptacle for terminal 30 of the front wiper relay in the PDC and the intermittent front wiper low speed circuit cavity of the instrument panel wire harness connector for the multi-function switch at all times. If OK, go to Step 2. If not OK, repair the open intermittent front wiper low speed circuit between the PDC and the multi-function switch as required. 2. The relay normally closed terminal (87A) is connected to the front wiper motor park switch through the CTM on the front wiper park switch sense circuit. There should be continuity between the receptacle for terminal 87A of the front wiper relay in the PDC and the front wiper park switch sense circuit cavity of the headlamp and dash wire harness connector for the wiper motor at all times. If OK, go to Step 3. If not OK, repair the open front wiper park switch sense circuit between the PDC and the front wiper motor as required. 3. The relay normally open terminal (87) is connected to a fused ignition switch output (run-acc) fuse in the Junction Block (JB) through a fused ignition switch output (run-acc) circuit. There should be battery voltage at the receptacle for terminal 87 of the front wiper relay in the PDC whenever the ignition switch is in the ON or Accessory positions. If OK, go to Step 4. If not OK, repair the open fused ignition switch output (run-acc) circuit between the PDC and the JB as required. 4. The coil battery terminal (86) is connected to a fused ignition switch output (run-acc) fuse in the JB through a fused ignition switch output (run-acc) circuit. There should be battery voltage at the receptacle for terminal 86 of the front wiper relay in the PDC whenever the ignition switch is in the ON or Accessory positions. If OK, go to Step 5. If not OK, repair the open fused ignition switch output (run-acc) circuit between the PDC and the JB as required. 5. The coil ground terminal (85) is connected to the output of the Central Timer Module (CTM) through the wiper relay control circuit. There should be continuity between the receptacle for terminal 85 of the front wiper relay in the PDC and the wiper relay control circuit cavity of the instrument panel wire harness connector (Connector C3) for the CTM at all times. If not OK, repair the open wiper relay control circuit between the PDC and the CTM as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Front Wiper Relay Test > Page 465 Wiper Relay: Testing and Inspection Rear Wiper Relay Test Fig. 14 Rear Wiper Relay The rear wiper relay is located in the Power Distribution Center (PDC) in the engine compartment. See the fuse and relay layout label affixed to the inside surface of the PDC cover for rear wiper relay identification and location. 1. Remove the rear wiper relay from the PDC. (Refer to REAR WIPER RELAY - REMOVAL). 2. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 4. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, test the relay input and output circuits. Refer to RELAY CIRCUIT TEST. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to the multi-function switch. There should be continuity between the receptacle for terminal 30 of the rear wiper relay in the PDC and the rear wiper motor control circuit cavity of the liftgate wire harness connector for the rear wiper motor at all times. If OK, go to Step 2. If not OK, repair the open rear wiper motor control circuit between the PDC and the rear wiper motor as required. 2. The relay normally closed terminal (87A) is connected to ground. There should be continuity between the receptacle for terminal 87A of the rear wiper relay in the PDC and a good ground at all times. If OK, go to Step 3. If not OK, repair the open ground circuit to ground (G113) as required. 3. The relay normally open terminal (87) is connected to a fused B(+) fuse in the PDC through a fused B(+) circuit. There should be battery voltage at the receptacle for terminal 87 of the rear wiper relay at all times. If OK, go to Step 4. If not OK, repair the open B(+) circuit between the PDC and the battery as required. 4. The coil battery terminal (86) is connected to a fused B(+) fuse in the PDC through a fused B(+) circuit. There should be battery voltage at the receptacle for terminal 86 of the rear wiper relay at all times. If OK, go to Step 5. If not OK, repair the open B(+) circuit between the PDC and the battery as required. 5. The coil ground terminal (85) is connected to the output of the Central Timer Module (CTM) through the rear wiper relay control circuit. There should be continuity between the receptacle for terminal 85 of the rear wiper relay in the PDC and the rear wiper relay control circuit cavity of the instrument panel wire harness connector (Connector C3) for the CTM at all times. If not OK, repair the open rear wiper relay control circuit between the PDC and the CTM as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Service and Repair > Front Wiper Relay Replacement Wiper Relay: Service and Repair Front Wiper Relay Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. Fig. 10 Power Distribution Center - Typical 2. Remove the cover from the Power Distribution Center (PDC). 3. See the fuse and relay layout label affixed to the underside of the PDC cover for front wiper relay identification and location. 4. Remove the front wiper relay by grasping it firmly and pulling it straight out from the receptacle in the PDC. INSTALLATION 1. See the fuse and relay layout label affixed to the underside of the PDC cover for the proper front wiper relay location. 2. Position the front wiper relay in the proper receptacle in the PDC. 3. Align the front wiper relay terminals with the terminal cavities in the PDC receptacle. 4. Push firmly and evenly on the top of the front wiper relay until the terminals are fully seated in the terminal cavities in the PDC receptacle. 5. Reinstall the cover onto the PDC. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Service and Repair > Front Wiper Relay Replacement > Page 468 Wiper Relay: Service and Repair Rear Wiper Relay Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. Fig. 15 Power Distribution Center - Typical 2. Remove the cover from the Power Distribution Center (PDC) . 3. See the fuse and relay layout label affixed to the underside of the PDC cover for rear wiper relay identification and location. 4. Remove the rear wiper relay by grasping it firmly and pulling it straight out from the receptacle in the PDC. Fig. 10 Rear Wiper Blade INSTALLATION 1. See the fuse and relay layout label affixed to the underside of the PDC cover for the proper rear wiper relay location. 2. Position the rear wiper relay in the proper receptacle in the PDC. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Service and Repair > Front Wiper Relay Replacement > Page 469 3. Align the rear wiper relay terminals with the terminal cavities in the PDC receptacle. 4. Push firmly and evenly on the top of the rear wiper relay until the terminals are fully seated in the terminal cavities in the PDC receptacle. 5. Reinstall the cover onto the PDC. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 475 Lock Cylinder Switch: Diagrams Driver Cylinder Lock Switch Liftgate Cylinder Lock Switch Passenger Cylinder Lock Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 476 Lock Cylinder Switch: Description and Operation DOOR CYLINDER LOCK SWITCH A door cylinder lock switch is snapped onto the back of the key lock cylinder inside each front door. The door cylinder lock switch is a resistor multiplexed momentary switch that is hard wired in series between a body ground and the Central Timer Module (CTM) through the front door wire harness. The door cylinder lock switches are driven by the key lock cylinders and contain three internal resistors. One resistor is used for the neutral switch position, one for the Lock position, and one for the Unlock position. The door cylinder lock switches cannot be adjusted or repaired and, if faulty or damaged, they must be replaced. The door cylinder lock switches are actuated by the key lock cylinder when the key is inserted in the lock cylinder and turned to the lock or unlock positions. The door cylinder lock switch closes a path to ground through one of three internal resistors for the Central Timer Module (CTM) when the front door key lock cylinder is in the Lock, Unlock, or Neutral positions. The CTM reads the switch status through an internal pull-up, then uses this information as an input for both power lock system and Vehicle Theft Security System (VTSS) operation. The door cylinder lock switches and circuits can be diagnosed using conventional diagnostic tools and methods. LIFTGATE CYLINDER LOCK SWITCH The liftgate cylinder lock switch is snapped onto the back of the liftgate key lock cylinder inside the liftgate. The liftgate cylinder lock switch is a resistor multiplexed momentary switch that is hard wired in series between a body ground and the Central Timer Module (CTM) through the liftgate wire harness. The liftgate cylinder lock switch is driven by the key lock cylinder and contains three internal resistors. One resistor is used for the neutral switch position, one for the Lock position and one for the Unlock position. The liftgate cylinder lock switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The liftgate cylinder lock switch is actuated by the key lock cylinder when the key is inserted in the lock cylinder and turned to the lock or unlock positions. The liftgate cylinder lock switch closes a path to ground through one of three internal resistors for the Central Timer Module (CTM) when the liftgate key lock cylinder is in the Lock, Unlock, or Neutral positions. The CTM reads the switch status through an internal pull-up, then uses this information as an input for both the power lock system and Vehicle Theft Security System (VTSS) operation. The liftgate cylinder lock switch and circuits can be diagnosed using conventional diagnostic tools and methods. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Testing and Inspection > Door Cylinder Lock Switch Test Lock Cylinder Switch: Testing and Inspection Door Cylinder Lock Switch Test 1. Disconnect the door cylinder lock switch pigtail wire connector from the door wire harness connector. DOOR LOCK CYLINDER SWITCH 2. Using an ohmmeter, perform the switch resistance checks between the two cavities of the door cylinder lock switch pigtail wire connector. Actuate the switch by rotating the key in the door lock cylinder to test for the proper resistance values in each of the three switch positions, as shown in the Door Cylinder Lock Switch chart. 3. If a door cylinder lock switch fails any of the resistance tests, replace the faulty switch as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Testing and Inspection > Door Cylinder Lock Switch Test > Page 479 Lock Cylinder Switch: Testing and Inspection Liftgate Cylinder Lock Switch Test 1. Disconnect the liftgate cylinder lock switch pigtail wire connector from the liftgate wire harness connector. Liftgate Cylinder Lock Switch 2. Using an ohmmeter, perform the switch resistance checks between the two cavities of the liftgate cylinder lock switch pigtail wire connector. Actuate the switch by rotating the key in the liftgate lock cylinder to test for the proper resistance values in each of the three switch positions, as shown in the Liftgate Cylinder Lock Switch chart. 3. If a liftgate cylinder lock switch fails any of the resistance tests, replace the faulty switch as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Service and Repair > Door Cylinder Lock Switch Replacement Lock Cylinder Switch: Service and Repair Door Cylinder Lock Switch Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door outside latch handle mounting hardware and linkage from the inside of the door. Door Lock Cylinder Switch Remove/Install - Typical 3. From the outside of the door, pull the door outside latch handle out from the door far enough to access the door cylinder lock switch. 4. Disengage the door cylinder lock switch from the back of the lock cylinder. 5. Disconnect the door cylinder lock switch pigtail wire connector from the door wire harness connector. 6. Disengage the retainers that secure the door cylinder lock switch pigtail wire harness to the inner door panel. 7. Remove the door cylinder lock switch from the door. INSTALLATION 1. Position the door cylinder lock switch into the door. 2. Engage the retainers that secure the door cylinder lock switch pigtail wire harness to the inner door panel. 3. Reconnect the door cylinder lock switch pigtail wire connector to the door wire harness connector. 4. Reinstall the door cylinder lock switch onto the back of the lock cylinder. 5. Reinstall the door outside latch handle mounting hardware and linkage on the inside of the door. 6. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Service and Repair > Door Cylinder Lock Switch Replacement > Page 482 Lock Cylinder Switch: Service and Repair Liftgate Cylinder Lock Switch Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the liftgate inner panel. Liftgate Lock Cylinder Switch Remove/Install 3. Reach through the access hole in the liftgate inner panel to access and disengage the liftgate cylinder lock switch from the back of the lock cylinder. 4. Disconnect the liftgate cylinder lock switch pigtail wire connector from the liftgate wire harness connector. 5. Disengage the retainers that secure the liftgate cylinder lock switch pigtail wire harness to the liftgate inner panel. 6. Remove the liftgate cylinder lock switch from the liftgate. INSTALLATION 1. Position the liftgate cylinder lock switch into the liftgate. 2. Engage the retainers that secure the liftgate cylinder lock switch pigtail wire harness to the liftgate inner panel. 3. Reconnect the liftgate cylinder lock switch pigtail wire connector to the liftgate wire harness connector. 4. Reinstall the trim panel onto the liftgate inner panel. 5. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations Remote Switch: Locations The two remote radio switchs are retained in mounting holes located on each side of the rear steering wheel trim cover by four latches that are integral to the switches. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 486 Remote Switch: Diagrams Left Remote Radio Switch (Premium) Right Remote Radio Switch (Premium) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 487 Remote Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 488 Remote Switch: Description and Operation A remote radio switch option is available on models equipped with the AM/FM/CD/cassette/3-band graphic equalizer radio receiver and the high-line Central Timer Module (CTM). (Refer to ELECTRONIC CONTROL MODULES/BODY CONTROL/CENTRAL TIMER MODULE DESCRIPTION). Fig. 13 Remote Radio Switches Two rocker-type switches are mounted in the sides of the rear (instrument panel side) steering wheel trim cover. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. The switch on the right spoke also includes a "mode" control that allows the driver to sequentially select AM radio, FM radio, cassette player or CD player. The two switches are retained in mounting holes located on each side of the rear steering wheel trim cover by four latches that are integral to the switches. The remote radio switches share a common steering wheel wire harness with the vehicle speed control switches. The steering wheel wire harness is connected to the instrument panel wire harness through the clockspring. (Refer to CLOCKSPRING - DESCRIPTION). The remote radio switches are resistor multiplexed units that are hard wired to the high-line CTM through the clockspring. The CTM monitors the status of the remote radio switches and sends the proper switch status messages on the J1850 data bus network to the radio receiver. The electronic circuitry within the radio is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. For diagnosis of the CTM or the J1850 data bus, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended. For more information on the features and control functions for each of the remote radio switches, see the owner's manual in the vehicle glove box. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 489 Remote Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Fig. 14 Remote Radio Switches 1. Remove the remote radio switch(es) from the steering wheel. Remote Radio Switch Test 2. Use an ohmmeter to check the switch resistances as shown in the Remote Radio Switch Test chart. If the remote radio switch resistances check OK, go to Step 3. If not OK, replace the faulty switch. 3. Check for continuity between the ground circuit cavity of the remote radio switch wire harness connector and a good ground. There should be continuity. If OK, go to Step 4. If not OK, repair the open ground circuit to ground as required. 4. Disconnect the 18-way wire harness connector from the Central Timer Module (CTM). Check for continuity between the radio control mux circuit cavity of the remote radio switch wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted radio control mux circuit as required. 5. Check for continuity between the radio control mux circuit cavities of the remote radio switch wire harness connector and the 18-way CTM wire harness connector. There should be continuity. If OK, refer to the proper Diagnostic Procedures to test the CTM and the J1850 data bus. If not OK, repair the open radio control mux circuit as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 490 Remote Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side airbag module from the steering wheel. (Refer to DRIVER AIRBAG - REMOVAL). 3. Remove the speed control switch located on the same side of the steering wheel as the remote radio switch that is being serviced. (Refer to SPEED CONTROL/SWITCH - REMOVAL). Fig. 15 Remote Radio Switches Remove/Install 4. Disconnect the steering wheel wire harness connector from the connector receptacle of the remote radio switch. 5. Disengage the four remote radio switch latches that secure the switch to the inside of the mounting hole in the steering wheel rear trim cover 6. From the outside of the steering wheel rear trim cover, remove the remote radio switch from the trim cover mounting hole. INSTALLATION 1. Position the remote radio switch to the mounting hole on the outside of the steering wheel rear trim cover. Be certain that the connector receptacle is oriented toward the bottom of the switch and pointed toward the center of the steering wheel. 2. Press firmly and evenly on the remote radio switch until each of the switch latches is fully engaged in the mounting hole of the steering wheel rear trim cover. 3. Reconnect the steering wheel wire harness connector to the connector receptacle of the remote radio switch. 4. Install the speed control switch onto the steering wheel. (Refer to SPEED CONTROL/SWITCH - INSTALLATION). 5. Install the driver side airbag module onto the steering wheel. (Refer to DRIVER AIRBAG - INSTALLATION). 6. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Road Temperature Sensor > Component Information > Description and Operation Road Temperature Sensor: Description and Operation AMBIENT TEMPERATURE SENSOR Ambient air temperature is monitored by the compass mini-trip computer module through the ambient temperature sensor. The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the right side of the radiator yoke, behind the radiator grille and in front of the engine compartment. For complete circuit diagrams, refer to Overhead Console in the Contents of Wiring Diagrams. The ambient temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent to it by the compass mini-trip computer module. The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the compass mini-trip computer module. Based upon the resistance in the sensor, the compass mini-trip computer module senses a specific voltage on the temperature sensor signal circuit, which it is programmed to correspond to a specific temperature. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Road Temperature Sensor > Component Information > Description and Operation > Page 494 Road Temperature Sensor: Testing and Inspection The thermometer function is supported by the ambient temperature sensor, a wiring circuit, and a portion of the compass mini-trip computer module. If any portion of the ambient temperature sensor circuit fails, the compass/thermometer display function will self-diagnose the circuit. An "SC" (short circuit) will appear in the display in place of the temperature, when the sensor is exposed to temperatures above 110 °C (230 °F), or if the sensor circuit is shorted. An "OC", (open circuit) will appear in the display in place of the temperature, when the sensor is exposed to temperatures below -50 °C (-58 ° F), or if the sensor circuit is open. The ambient temperature sensor circuit can also be diagnosed using the following Sensor Test, and Sensor Circuit Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, refer to Compass Mini-Trip Computer in the Diagnosis and Testing. For complete circuit diagrams, refer to Overhead Console in the Contents of Wiring Diagrams. Sensor Test 1. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor wire harness connector. 2. Measure the resistance of the ambient temperature sensor. At -40 °C (-40 °F), the sensor resistance is 336 kilo ohms. At -55 °C (131 °F), the sensor resistance is 2.488 kilo ohms. The sensor resistance should read between these two values. If OK, refer to Sensor Circuit Test in the Diagnosis and Testing. If not OK, replace the faulty ambient temperature sensor. Sensor Circuit Test 1. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor wire harness connector and the overhead console wire harness connector. 2. Connect a jumper wire between the two terminals in the body half of the ambient temperature sensor wire harness connector. 3. Check for continuity between the sensor return circuit and the ambient temperature sensor signal circuit cavities of the roof wire harness overhead console connector. There should be continuity. If OK, go to Step 4. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 4. Remove the jumper wire from the body half of the ambient temperature sensor wire harness connector. Check for continuity between the sensor return circuit cavity of the roof wire harness overhead console connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted sensor return circuit as required. 5. Check for continuity between the ambient temperature sensor signal circuit cavity of the roof wire harness overhead console connector and a good ground. There should be no continuity. If OK, refer to Compass Mini-Trip Computer in the Diagnosis and Testing. If not OK, repair the shorted ambient temperature sensor signal circuit as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Road Temperature Sensor > Component Information > Description and Operation > Page 495 Road Temperature Sensor: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Fig.6 Ambient Temperatute Sensor Remove/Install 2. Locate the ambient temperature sensor, on the right side of the radiator yoke behind the grille. 3. Disconnect the wire harness connector from the ambient temperature sensor connector receptacle. 4. Remove the one screw that secures the ambient temperature sensor bracket to the radiator yoke. 5. Remove the ambient temperature sensor from the radiator yoke. INSTALLATION 1. Position the ambient temperature sensor onto the radiator yoke. 2. Install and tighten the one screw that secures the ambient temperature sensor bracket to the radiator yoke. Tighten the screw to 5.6 Nm (50 in. lbs.) . 3. Reconnect the wire harness connector to the ambient temperature sensor connector receptacle. 4. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams Passenger Door Power Lock Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 500 Power Door Lock Switch: Description and Operation The power lock system can be controlled by a two way, momentary, resistor multiplexed, single gang switch on a power lock and window switch bezel located near the forward end of the armrest on the passenger side front door trim panel. The power lock switch on the driver side front door trim panel is integral to the driver door module. (Refer to POWER LOCKS/DRIVER DOOR MODULE DESCRIPTION). The power lock switch is secured by integral latch tabs in a molded plastic receptacle on the back side of the power window and lock switch bezel so that only the switch paddle is visible where it protrudes through the bezel. The power window and lock switch bezel is secured by small metal snap clips within an opening near the forward end of the arm rest in the passenger side front door trim panel so that the switches can be serviced without removing the front door trim panel. An integral connector receptacle on the back of the switch connects it to the vehicle electrical system through a take out and connector of the right front door wire harness. The power lock switch has a green Light-Emitting Diode (LED) located in the switch paddle to improve switch visibility in dark ambient lighting conditions. The power lock switch cannot be adjusted or repaired and, if faulty or damaged, the switch unit must be replaced. The two-way, momentary, power lock switch on the passenger side front door is connected in series between ground and the passenger door switch mux input of the Central Timer Module (CTM). The power lock switch on the driver side front door trim panel is integral to the driver door module. (Refer to POWER LOCKS/DRIVER DOOR MODULE - OPERATION). Each power lock switch position Lock, Unlock, and Neutral provides a different resistance value to the CTM input which allows the CTM to sense the switch position. Based upon the power lock switch inputs, the CTM controls the battery and ground feed outputs to the power lock motors to lock or unlock the door and liftgate latches. The Light-Emitting Diode (LED) in the paddle of the passenger door power lock switch is connected to battery current through a fuse in the Junction Block (JB) on a fused ignition switch output (run) circuit; therefore, the switch will only be illuminated when the ignition switch is in the On position. The power lock switch can be diagnosed using conventional diagnostic tools and methods. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 501 Power Door Lock Switch: Testing and Inspection The Light-Emitting Diode (LED) illumination lamp of the power lock switch receives battery current through a fuse in the Junction Block (JB) on a fused ignition switch output (run) circuit. The power lock switch on the driver side front door trim panel is integral to the driver door module. (Refer to POWER LOCKS/DRIVER DOOR MODULE - DIAGNOSIS AND TESTING). If the power lock switch operates, but the LED is inoperative, check for battery current at the switch with the ignition switch in the ON position. If OK, replace the faulty switch. 1. Disconnect and isolate the battery negative cable. Remove the power lock switch from the door trim panel. Disconnect the door wire harness connector for the power lock switch from the switch connector receptacle. Power Lock Switch Test Fig.5 Powr Lock Switch Connector Receptable 2. Test the power lock switch resistance. See the Power Lock Switch Test chart to determine if the resistance is correct for the switch in each switch position. If not OK, replace the faulty power lock switch as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 502 Power Door Lock Switch: Service and Repair REMOVAL The power lock switch on the driver side front door trim panel is integral to the driver door module. (Refer to POWER LOCKS/DRIVER DOOR MODULE - REMOVAL). 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick or another suitable wide flat bladed tool and starting at the rear of the passenger door power window and lock switch bezel, gently pry the bezel up and out from the passenger side front door trim panel. 3. Pull the power window and lock switch bezel away from the trim panel opening far enough to access the two switch connector receptacles on the back of the unit. 4. Disconnect the door wire harness connectors for the power lock and power window switches from the switch connector receptacles. 5. Remove the power window and lock switch bezel from the door trim panel. 6. Using a small thin-bladed screwdriver, gently pry the snap clips at the sides of the power lock switch receptacle on the back of the power window and lock switch bezel and pull the switch out of the receptacle. INSTALLATION The power lock switch on the driver side front door trim panel is integral to the driver door module. (Refer to POWER LOCKS/DRIVER DOOR MODULE - INSTALLATION). 1. Align the power lock switch with the receptacle on the back of the power window and lock switch bezel. 2. Using hand pressure, gently and evenly press down on the power lock switch it snaps into place in the power window and lock switch bezel receptacle. 3. Position the power window and lock switch bezel to the opening in the passenger side front door trim panel. 4. Reconnect the two door wire harness connectors for the power window and power lock switches to the switch connector receptacles. 5. Insert the front of the power window and lock switch bezel into the opening in the passenger side front door trim panel. 6. Using hand pressure, gently and evenly press down on the rear of the power window and lock switch bezel until it snaps into place. 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection Power Mirror Switch: Testing and Inspection The power mirror switch is included with the Driver Door Module. (Refer to DOOR MODULE DIAGNOSIS AND TESTING) for service procedures. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Page 506 Power Mirror Switch: Service and Repair REMOVAL The power mirror switch is included with the Driver Door Module. (Refer to DOOR MODULE REMOVAL) for service procedures. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations Power Seat Switch: Locations The switch is located on the lower outboard side of the seat cushion on the seat cushion side shield on all models. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 510 Power Seat Switch: Diagrams Driver Power Seat Switch Passenger Power Seat Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 511 Power Seat Switch: Description and Operation DRIVER POWER SEAT SWITCH The power seat can be adjusted in six different ways using the power seat switch. The power seat switch for some models has an additional switch knob for adjusting the power lumbar support. The switch is located on the lower outboard side of the seat cushion on the seat cushion side shield on all models. Refer to the owner's manual in the vehicle glove box for more information on the power seat switch functions and the seat adjusting procedures. The individual switches in the power seat switch module cannot be repaired. If one switch is damaged or faulty, the entire power seat switch module must be replaced. When a power switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track or recliner adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. PASSENGER POWER SEAT SWITCH The power seat can be adjusted in six different ways using the power seat switch. The power seat switch for some models has an additional switch knob for adjusting the power lumbar support. The switch is located on the lower outboard side of the seat cushion on the seat cushion side shield on all models. Refer to the owner's manual in the vehicle glove box for more information on the power seat switch functions and the seat adjusting procedures. The individual switches in the power seat switch module cannot be repaired. If one switch is damaged or faulty, the entire power seat switch module must be replaced. When a power switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track or recliner adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver Power Seat Switch Test Power Seat Switch: Testing and Inspection Driver Power Seat Switch Test 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat. Driver Power Seat Switch Test Fig. 1 Driver Seat Switch 3. Use an ohmmeter to test the continuity of the power seat switches in each position. See the Power Seat Switch Continuity chart and figure. If OK, see Power Seat Adjuster and Motors or Power Lumbar Adjuster and Motor in the Diagnosis and Testing. If not OK, replace the faulty power seat switch unit. CAUTION: Be certain the two halves of the power seat switch assembly are completely snapped together. Failure to do so could result in a misdiagnosed power seat switch. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver Power Seat Switch Test > Page 514 Power Seat Switch: Testing and Inspection Passenger Power Seat Switch Test 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat. Passenger Power Seat Switch Test Fig. 2 Passenger Power Seat Switch 3. Use an ohmmeter to test the continuity of the power seat switches in each position. See the Power Seat Switch Continuity chart and figure. If OK, see Power Seat Adjuster and Motors or Power Lumbar Adjuster and Motor in the Diagnosis and Testing. If not OK, replace the faulty power seat switch unit. CAUTION: Be certain the two halves of the power seat switch assembly are completely snapped together. Failure to do so could result in a misdiagnosed power seat switch. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Driver Power Seat Switch Replacement Power Seat Switch: Service and Repair Driver Power Seat Switch Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the seat cushion side shield from the seat. Refer to Body for the procedure. 3. Pull the switch bezel or side shield unit out from the seat far enough to access the switch wire harness connector. Gently pry the locking tabs of the switch away from the wire harness connector and carefully unplug the connector from the power seat switch module. 4. Remove the screws that secure the power seat switch. INSTALLATION 1. Position the power seat switch on the seat cushion side shield and connect the electrical connector. 2. Install the screws that secure the power seat switch to seat cushion side shield. 3. Install the seat cushion side shield on the seat. Refer to Body for the procedure. 4. If equipped, install the recliner lever on the recliner mechanism release shaft. 5. If equipped, install the screw that secures the recliner lever to the recliner mechanism release shaft on the outboard side of the front seat. 6. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Driver Power Seat Switch Replacement > Page 517 Power Seat Switch: Service and Repair Passenger Power Seat Switch Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the seat cushion side shield from the seat. Refer to Body for the procedure. 3. Pull the switch bezel or side shield unit out from the seat far enough to access the switch wire harness connector. Gently pry the locking tabs of the switch away from the wire harness connector and carefully unplug the connector from the power seat switch module. 4. Remove the screws that secure the power seat switch. INSTALLATION 1. Position the power seat switch on the seat cushion side shield and connect the electrical connector. 2. Install the screws that secure the power seat switch to seat cushion side shield. 3. Install the seat cushion side shield on the seat. Refer to Body for the procedure. 4. If equipped, install the recliner lever on the recliner mechanism release shaft. 5. If equipped, install the screw that secures the recliner lever to the recliner mechanism release shaft on the outboard side of the front seat. 6. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams Seat Heater Switch: Diagrams Driver Heated Seat Switch Passenger Heated Seat Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Page 521 Seat Heater Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Page 522 Seat Heater Switch: Description and Operation DRIVER SEAT HEATER SWITCH The heated seat switches used on vehicles with this option are both mounted in the center console. The two switches are snapped into mounting holes in the center console. The two heated seat switches are identical in appearance and construction, except for the location of a keyway in the single connector receptacle and the housing on the back of each switch. The instrument panel wire harness connectors for the heated seat switches are keyed to match the connector receptacles on the switches so that the two heated seat switches can only be connected to the proper heated seat. The momentary, bidirectional rocker-type heated seat switch provides a resistor-multiplexed signal to the heated seat module. Each switch has a center neutral position and momentary Low and High positions so that both the driver and the front seat passenger can select a preferred seat heating mode. Each heated seat switch has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected mode (Low or High) of the seat heater for each seat and to provide diagnostic feedback for the heated seat system. Each switch also has three other LED indicator lamps, which provides back lighting of the switch nomenclature when the ignition switch is in the Run position. The five LED indicator lamps in each heated seat switch cannot be repaired. If the indicator or back lighting lamps are faulty or damaged, the individual heated seat switch unit must be replaced. The heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the ON position. Depressing the heated seat switch rocker to its momentary High or Low position provides a hard-wired resistor multiplexed voltage request signal to the heated seat module to power the heated seat element of the selected seat and maintain the requested temperature setting. If the heated seat switch is depressed to a different position (Low or High) than the currently selected state, the heated seat module will change states to support the new selection. If a heated seat switch is depressed a second time to the same position as the currently selected state, the heated seat module interprets the second input as a request to turn the seat heater OFF. The heated seat module will then turn the heated seat elements for that seat OFF. The indicator lamps in the heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the ON position. The ground side of each indicator lamp is controlled by a separate (high or low/driver or passenger) indicator lamp driver circuit by the heated seat module. The heated seat module control of the switch indicator lamps also allows the module to provide diagnostic feedback to the vehicle operator to indicate monitored heated seat system faults by flashing the indicator lamps ON and OFF. One side of the back lighting LED's in each heated seat switch are connected in series to ground at all times. The other side of the LED's are connected to the ignition switch run circuit. These LED's are energized when the ignition switch is turned to the Run position. PASSENGER SEAT HEATER SWITCH The heated seat switches used on vehicles with this option are both mounted in the center console. The two switches are snapped into mounting holes in the center console. The two heated seat switches are identical in appearance and construction, except for the location of a keyway in the single connector receptacle and the housing on the back of each switch. The instrument panel wire harness connectors for the heated seat switches are keyed to match the connector receptacles on the switches so that the two heated seat switches can only be connected to the proper heated seat. The momentary, bidirectional rocker-type heated seat switch provides a resistor-multiplexed signal to the heated seat module. Each switch has a center neutral position and momentary Low and High positions so that both the driver and the front seat passenger can select a preferred seat heating mode. Each heated seat switch has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected mode (Low or High) of the seat heater for each seat and to provide diagnostic feedback for the heated seat system. Each switch also has three other LED indicator lamps, which provides back lighting of the switch nomenclature when the ignition switch is in the Run position. The five LED indicator lamps in each heated seat switch cannot be repaired. If the indicator or back lighting lamps are faulty or damaged, the individual heated seat switch unit must be replaced. The heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the ON position. Depressing the heated seat switch rocker to its momentary High or Low position provides a hard-wired resistor multiplexed voltage request signal to the heated seat module to power the heated seat element of the selected seat and maintain the requested temperature setting. If the heated seat switch is depressed to a different position (Low or High) than the currently selected state, the heated seat module will change states to support the new selection. If a heated seat switch is depressed a second time to the same position as the currently selected state, the heated seat module interprets the second input as a request to turn the seat heater OFF. The heated seat module will then turn the heated seat elements for that seat OFF. The indicator lamps in the heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the ON position. The ground side of each indicator lamp is controlled by a separate (high or low/driver or passenger) indicator lamp driver circuit by the heated seat module. The heated seat module control of the switch indicator lamps also allows the module to provide diagnostic feedback to the vehicle operator to indicate monitored heated seat system faults by flashing the indicator lamps ON and OFF. One side of the back lighting LED's in each heated seat switch are connected in series to ground at all times. The other side of the LED's are connected to the ignition switch run circuit. These LED's are energized when the ignition switch is turned to the Run position. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Testing and Inspection > Driver Heated Seat Switch Test Seat Heater Switch: Testing and Inspection Driver Heated Seat Switch Test WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. If the problem being diagnosed involves inoperative heated seat switch back lighting and the heated seat elements do heat, disconnect the inoperative switch and check for continuity between the ground pin at the heated seat switch connector and ground. If there is no continuity, repair an open wire between ground and the heated seat switch connector. If there is continuity, replace the inoperative heated seat switch with a known good unit. If the problem being diagnosed involves inoperative heated seat switch back lighting and the heated seat elements do not heat, refer to Step 2. If the problem being diagnosed involves inoperative heated seat switch indicator lamps and the heated seat elements do not heat, refer to Step 2. If the problem being diagnosed involves inoperative heated seat switch indicator lamps, inoperative back lighting and the heated seat elements do heat, go to Step 6. If the problem being diagnosed involves a heated seat switch indicator lamp that remains illuminated after the heated seat has been turned OFF, refer to Heated Seat Module in Electronic Control Modules for the location of the proper heated seat module diagnosis and testing procedures. Also refer to the Body Diagnostic for additional diagnosis and testing procedures. 2. Check the fused ignition switch output (run) fuse in the Junction Block (JB). If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 3. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run) fuse in the JB. If OK, go to Step 4. If not OK, repair the open fused ignition switch output (run) circuit to the ignition switch as required. 4. Disconnect and isolate the battery negative cable. Remove the heated seat switch from the center console. Disconnect the wire harness connector from the connector receptacle on the back of the heated seat switch to be tested. Reconnect the battery negative cable. Turn the ignition switch to the Run position. Check for battery voltage at the fused ignition switch output (run) circuit cavity of the center console wire harness connector for the heated seat switch. If OK, go to Step 5. If not OK, repair the open fused ignition switch output (run) circuit to the JB fuse as required. Heated Seat Switch Continuity Chart 5. Check the continuity and resistance values of the heated seat switch in the Neutral, Low and High positions as shown in the Heated Seat Switch Continuity chart. If OK, refer to Heated Seat Module in Electronic Control Modules for the location of the proper heated seat module diagnosis and testing procedures. Also refer to the Body Diagnostic for additional diagnosis and testing procedures. If not OK, replace the faulty heated seat switch. 6. Replace the inoperative heated seat switch with a known good unit and test the operation of the switch indicator lamps. If OK, discard the faulty heated seat switch. If not OK, refer to Heated Seat Module in Electronic Control Modules for the location of the proper heated seat module diagnosis and testing procedures. Also refer to the Body Diagnostic for additional diagnosis and testing procedures. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Testing and Inspection > Driver Heated Seat Switch Test > Page 525 Seat Heater Switch: Testing and Inspection Passenger Heated Seat Switch Test WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. If the problem being diagnosed involves inoperative heated seat switch back lighting and the heated seat elements do heat, disconnect the inoperative switch and check for continuity between the ground pin at the heated seat switch connector and ground. If there is no continuity, repair an open wire between ground and the heated seat switch connector. If there is continuity, replace the inoperative heated seat switch with a known good unit. If the problem being diagnosed involves inoperative heated seat switch back lighting and the heated seat elements do not heat, refer to Step 2. If the problem being diagnosed involves inoperative heated seat switch indicator lamps and the heated seat elements do not heat, refer to Step 2. If the problem being diagnosed involves inoperative heated seat switch indicator lamps, inoperative back lighting and the heated seat elements do heat, go to Step 6. If the problem being diagnosed involves a heated seat switch indicator lamp that remains illuminated after the heated seat has been turned OFF, refer to Heated Seat Module in Electronic Control Modules for the location of the proper heated seat module diagnosis and testing procedures. Also refer to the Body Diagnostic for additional diagnosis and testing procedures. 2. Check the fused ignition switch output (run) fuse in the Junction Block (JB). If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 3. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run) fuse in the JB. If OK, go to Step 4. If not OK, repair the open fused ignition switch output (run) circuit to the ignition switch as required. 4. Disconnect and isolate the battery negative cable. Remove the heated seat switch from the center console. Disconnect the wire harness connector from the connector receptacle on the back of the heated seat switch to be tested. Reconnect the battery negative cable. Turn the ignition switch to the Run position. Check for battery voltage at the fused ignition switch output (run) circuit cavity of the center console wire harness connector for the heated seat switch. If OK, go to Step 5. If not OK, repair the open fused ignition switch output (run) circuit to the JB fuse as required. Heated Seat Switch Continuity Chart 5. Check the continuity and resistance values of the heated seat switch in the Neutral, Low and High positions as shown in the Heated Seat Switch Continuity chart. If OK, refer to Heated Seat Module in Electronic Control Modules for the location of the proper heated seat module diagnosis and testing procedures. Also refer to the Body Diagnostic for additional diagnosis and testing procedures. If not OK, replace the faulty heated seat switch. 6. Replace the inoperative heated seat switch with a known good unit and test the operation of the switch indicator lamps. If OK, discard the faulty heated seat switch. If not OK, refer to Heated Seat Module in Electronic Control Modules for the location of the proper heated seat module diagnosis and testing procedures. Also refer to the Body Diagnostic for additional diagnosis and testing procedures. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Driver Heated Seat Switch Replacement Seat Heater Switch: Service and Repair Driver Heated Seat Switch Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a small flat bladed pry tool, gently pry the lower right side edge of the seat heater switch out of its mounting location in the center console. 3. Pull the heated seat switch out far enough to access and disconnect the center console wire harness connector from the connector receptacle on the back of the heated seat switch. 4. Remove the heated seat switch from the center console. INSTALLATION 1. Connect the center console wire harness connector on the connector receptacle on the back of the heated seat switch. 2. Install the heated seat switch in the center console mounting hole. 3. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Driver Heated Seat Switch Replacement > Page 528 Seat Heater Switch: Service and Repair Passenger Heated Seat Switch Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a small flat bladed pry tool, gently pry the lower right side edge of the seat heater switch out of its mounting location in the center console. 3. Pull the heated seat switch out far enough to access and disconnect the center console wire harness connector from the connector receptacle on the back of the heated seat switch. 4. Remove the heated seat switch from the center console. INSTALLATION 1. Connect the center console wire harness connector on the connector receptacle on the back of the heated seat switch. 2. Install the heated seat switch in the center console mounting hole. 3. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams Liftgate Ajar Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Page 532 Trunk / Liftgate Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Page 533 Trunk / Liftgate Switch: Description and Operation LIFTGATE AJAR SWITCH The liftgate ajar switch is integral to the latch on the liftgate. The switch closes a path to ground for the Central Timer Module (CTM) when the liftgate is opened, and opens the ground path when the liftgate is closed. The liftgate ajar switch cannot be repaired and, if faulty or damaged, the liftgate latch unit must be replaced. The liftgate ajar switch closes a path to ground for the Central Timer Module (CTM) when the liftgate is opened, and opens the ground path when the liftgate is closed. The liftgate ajar switch is connected in series between ground and the CTM to provide a unique input. The CTM reads the switch status through an internal pull-up, then sends the proper switch status messages to other electronic modules over the Programmable Communications Interface (PCI) data bus network. The liftgate ajar switch can be diagnosed using conventional diagnostic tools and methods. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Page 534 Trunk / Liftgate Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Disconnect the liftgate latch pigtail wire connector from the liftgate wire harness connector. Check for continuity between the ground circuit cavity in the liftgate wire harness connector and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the open ground circuit to ground as required. 2. Check for continuity between the ground circuit cavity and the liftgate ajar switch sense circuit cavity in the liftgate latch pigtail wire connector. There should be continuity with the liftgate opened, and no continuity with the liftgate closed. If OK, go to Step 3. If not OK, replace the faulty liftgate latch unit. 3. Disconnect the body wire harness connector (Connector C2) for the Central Timer Module (CTM) from the CTM connector receptacle. Check for continuity between the liftgate ajar switch sense circuit cavity of the body wire harness connector (Connector C2) and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, repair the shorted liftgate ajar switch sense circuit between the liftgate latch and the CTM as required. 4. Check for continuity between the liftgate ajar switch sense circuit cavities of the body wire harness connector (Connector C2) and the liftgate wire harness connector for the liftgate latch. There should be continuity. If OK, use a DRB III scan tool to diagnose the CTM. Refer to the appropriate diagnostic procedures. If not OK, repair the open liftgate ajar switch sense circuit between the liftgate latch and the CTM as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Four Wheel Antilock Brake System Wheel Speed Sensor: Specifications Wheel Speed Sensors Front Sensor Bolt 190 in.lb Rear Sensor Bolt 200 in.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Four Wheel Antilock Brake System > Page 540 Wheel Speed Sensor: Specifications Wheel Speed Sensor Mounting Bolt 200 in.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations Wheel Speed Sensor: Component Locations Front Wheel Speed Sensor/Tone Wheels Rear Wheel Speed Sensors/Tone Wheels Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 543 Wheel Speed Sensor: Connector Locations Left Front Wheel Speed Sensor Connector Right Front Wheel Speed Sensor Connector Rear Wheel Speed Sensor Connector Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 544 Wheel Speed Sensor: Diagrams Left Front Wheel Speed Sensor (Sensor Side) Left Front Wheel Speed Sensor Rear Wheel Speed Sensor Right Front Wheel Speed Sensor (Sensor Side) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 545 Right Front Wheel Speed Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Rear Wheel Antilock Brake System Wheel Speed Sensor: Description and Operation Rear Wheel Antilock Brake System DESCRIPTION The rear Wheel Speed Sensor (WSS) is mounted in the rear differential housing. The exciter ring is press fitted onto the differential carrier next to the final drive ring gear. For replacement procedure of the exciter ring. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Rear Wheel Antilock Brake System > Page 548 Wheel Speed Sensor: Description and Operation Wheel Speed Sensor OPERATION The WSS consists of a magnet surrounded by windings from a single strand of wire. The sensor sends a small AC signal to the CAB. This signal is generated by magnetic induction. The magnetic induction is created when a toothed sensor ring (exciter ring or tone wheel) passes the stationary magnetic WSS. When the ring gear is rotated, the exciter ring passes the tip of the WSS. As the exciter ring tooth approaches the tip of the WSS, the magnetic lines of force expand, causing the magnetic field to cut across the sensor's windings. This, in turn causes current to flow through the WSS circuit in one direction. When the exciter ring tooth moves away from the sensor tip, the magnetic lines of force collapse cutting the winding in the opposite direction. This causes the current to flow in the opposite direction. Every time a tooth of the exciter ring passes the tip of the WSS, an AC signal is generated. Each AC signal (positive to negative signal or sinewave) is interpreted by the CAB. It then compares the frequency of the sinewave to a time value to calculate vehicle speed. The CAB continues to monitor the frequency to determine a deceleration rate that would indicate a possible wheel-locking tendency. The signal strength of any magnetic induction sensor is directly affected by: - Magnetic field strength; the stronger the magnetic field, the stronger the signal - Number of windings in the sensor; more windings provide a stronger signal - Exciter ring speed; the faster the exciter ring/tone wheel rotates, the stronger the signal will be - Distance between the exciter ring teeth and WSS; the closer the WSS is to the exciter ring/tone wheel, the stronger the signal will be The rear WSS is not adjustable. A clearance specification has been established for manufacturing tolerances. If the clearance is not within these specifications, then either the WSS or other components may be damaged. The clearance between the WSS and the exciter ring is 0.005 0.050 inch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Rear Wheel Antilock Brake System > Page 549 The assembly plant performs a "Rolls Test" on every vehicle that leaves the assembly plant. One of the test performed is a test of the WSS. To properly test the sensor, the assembly plant connects test equipment to the Data Link Connector (DLC). This connector is located to the right of the steering column and attached to the lower portion of the instrument panel. The rolls test terminal is spliced to the WSS circuit. The vehicle is then driven on a set of rollers and the WSS output is monitored for proper operation. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 REMOVAL - 2WD (1) Raise and support vehicle. (2) Remove bolt attaching sensor to the steering knuckle. (3) Remove clamps securing sensor wire to control arm and inner fender panel. (4) In engine compartment, disconnect sensor wire from harness and remove sensor. INSTALLATION - 2WD (1) Position sensor in the knuckle and install sensor attaching bolts. Tighten bolts to 21 Nm (190 inch lbs.). (2) Secure sensor wire retaining clamps to control arm and fender panel. (3) In engine compartment, connect sensor wire to harness connector. Make sure wire is routed away from hot or rotating underhood components. (4) Turn steering wheel back and forth to verify that wire is clear of steering and suspension components. (5) Remove supports and lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 552 Wheel Speed Sensor: Service and Repair Rear REAR WHEEL SPEED SENSOR REMOVAL (1) Raise vehicle on hoist. (2) Remove brake line mounting nut and remove the brake line from the sensor stud. (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 O-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 (200 inch lbs.). (6) Install the brake line on the sensor stud and install the nut. (7) Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications Engine Coolant Temperature (ECT) Sensor: Specifications Engine Coolant Temperature Sensor ....................................................................................................................................................... 11 Nm (96 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 558 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 559 Engine Coolant Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 560 Engine Coolant Temperature (ECT) Sensor: Description and Operation DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: ^ for engine coolant temperature gauge operation through CCD or PCI (J1850) ^ Communications ^ Injector pulse-width ^ Spark-advance curves ^ ASD relay shut-down times ^ Idle Air Control (IAC) motor key-on steps ^ Pulse-width prime-shot during cranking ^ 02 sensor closed loop times ^ Purge solenoid on/off times ^ EGR solenoid on/off times (if equipped) ^ Leak Detection Pump operation (if equipped) ^ Radiator fan relay on/off times (if equipped) ^ Target idle speed Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 561 Engine Coolant Temperature (ECT) Sensor: Service and Repair REMOVAL - 4.7L WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. The ECT sensor is located near the front of the intake manifold. 1. Partially drain cooling system. 2. Disconnect electrical connector from ECT sensor. 3. Remove sensor from intake manifold. INSTALLATION - 4.7L 1. Install sensor. 2. Tighten to 11 Nm (8 ft. lbs.) torque. 3. Connect electrical connector to sensor. 4. Replace any lost engine coolant. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications Cruise Control Switch: Specifications Switch Module Mounting Screws ........................................................................................................................................................... 1.5 Nm (14 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 566 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 567 Cruise Control Switch: Diagrams Left Speed Control Switch Right Speed Control Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 568 Cruise Control Switch: Service Precautions WARNING: BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION, REMOVE AND ISOLATE THE NEGATIVE (-) CABLE FROM THE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. THEN WAIT TWO MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 569 Cruise Control Switch: Description and Operation There are two separate switch pods that operate the speed control system. The steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM for ON, OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. Refer to the owner's manual for more information on speed control switch functions and setting procedures. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. When speed control is selected by depressing the ON, OFF switch, the PCM allows a set speed to be stored in its RAM for speed control. To store a set speed, depress the SET switch while the vehicle is moving at a speed between approximately 35 and 85 mph. In order for the speed control to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral. The speed control can be disengaged manually by: - Stepping on the brake pedal - Depressing the OFF switch - Depressing the CANCEL switch. The speed control can be disengaged also by any of the following conditions: - An indication of Park or Neutral - The VSS signal increases at a rate of 10 mph per second (indicates that the co-efficient of friction between the road surface and tires is extremely low) - Depressing the clutch pedal. - Excessive engine rpm (indicates that the transmission may be in a low gear) - The VSS signal decreases at a rate of 10 mph per second (indicates that the vehicle may have decelerated at an extremely high rate) - If the actual speed is not within 20 mph of the set speed The previous disengagement conditions are programmed for added safety. Once the speed control has been disengaged, depressing the ACCEL switch restores the vehicle to the target speed that was stored in the PCM's RAM. NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's RAM. If, while the speed control is engaged, the driver wishes to increase vehicle speed, the PCM is programmed for an acceleration feature. With the ACCEL switch held closed, the vehicle accelerates slowly to the desired speed. The new target speed is stored in the PCM's RAM when the ACCEL switch is released. The PCM also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph for each momentary switch activation of the ACCEL switch. The PCM also provides a means to decelerate without disengaging speed control. To decelerate from an existing recorded target speed, depress and hold the COAST switch until the desired speed is reached. Then release the switch. The ON, OFF switch operates two components: the PCM's ON, OFF input, and the battery voltage to the brake switch, which powers the speed control servo. Multiplexing The PCM sends out 5 volts through a fixed resistor and monitors the voltage change between the fixed resistor and the switches. If none of the switches are depressed, the PCM will measure 5 volts at the sensor point (open circuit). If a switch with no resistor is closed, the PCM will measure 0 volts (grounded circuit). Now, if a resistor is added to a switch, then the PCM will measure some voltage proportional to the size of the resistor. By adding a different resistor to each switch, the PCM will see a different voltage depending on which switch is pushed. Another resistor has been added to the 'at rest circuit' causing the PCM to never see 5 volts. This was done for diagnostic purposes. If the switch circuit should open (bad connection), then the PCM will see the 5 volts and know the circuit is bad. The PCM will then set an open circuit fault. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 570 Cruise Control Switch: Service and Repair REMOVAL WARNING: BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION, REMOVE AND ISOLATE THE NEGATIVE (-) CABLE FROM THE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. THEN WAIT TWO MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE INJURY. 1. Disconnect and isolate negative battery cable. 2. Remove airbag module. Refer to Passive Restraint Systems for procedures. Speed Control Switches 3. Remove switch-to-steering wheel mounting screws. 4. Remove switch. 5. Remove electrical connector at switch. INSTALLATION 1. Install electrical connector to switch. 2. Install switch and mounting screws. 3. Tighten screws to 1.5 Nm (14 in. lbs.) torque. 4. Install airbag module. Refer to Passive Restraint Systems for procedures. 5. Connect negative battery cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams Engine Oil Pressure Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Page 575 Oil Pressure Sensor: Description and Operation DESCRIPTION The 2-wire, electrical/mechanical engine oil pressure sensor (sending unit) is located in an engine oil pressure gallery. OPERATION The oil pressure sensor uses two circuits. They are: ^ A signal to the PCM relating to engine oil pressure ^ A sensor ground through the PCM's sensor return The oil pressure sensor returns a voltage signal back to the PCM relating to engine oil pressure. This signal is then transferred (bussed) to the instrument panel on a CCD bus circuit to operate the oil pressure gauge and the check gauges lamp. Ground for the sensor is provided by the PCM through a low noise sensor return. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Page 576 Oil Pressure Sensor: Service and Repair REMOVAL 1. Disconnect the negative cable from the battery. 2. Raise vehicle on hoist. 3. Remove front splash shield. 4. Disconnect oil pressure sender wire (Fig. 107). 5. Remove the pressure sender (Fig. 107). INSTALLATION 1. Install oil pressure sender. 2. Connect oil pressure sender wire. 3. Install front splash shield. 4. Lower vehicle. 5. Connect the negative battery cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams Ambient Temperature Sensor / Switch HVAC: Diagrams Ambient Temperature Sensor Ambient Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Page 581 Ambient Temperature Sensor / Switch HVAC: Description and Operation AMBIENT TEMP SENSOR - FRONT Ambient air temperature is monitored by the compass mini-trip computer module through the ambient temperature sensor. The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the right side of the radiator yoke, behind the radiator grille and in front of the engine compartment. For complete circuit diagrams, refer to Overhead Console in the Contents of Wiring Diagrams. The ambient temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent to it by the compass mini-trip computer module. The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the compass mini-trip computer module. Based upon the resistance in the sensor, the compass mini-trip computer module senses a specific voltage on the temperature sensor signal circuit, which it is programmed to correspond to a specific temperature. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Page 582 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection The thermometer function is supported by the ambient temperature sensor, a wiring circuit, and a portion of the compass mini-trip computer module. If any portion of the ambient temperature sensor circuit fails, the compass/thermometer display function will self-diagnose the circuit. An "SC" (short circuit) will appear in the display in place of the temperature, when the sensor is exposed to temperatures above 110 °C (230 °F), or if the sensor circuit is shorted. An "OC", (open circuit) will appear in the display in place of the temperature, when the sensor is exposed to temperatures below -50 °C (-58 ° F), or if the sensor circuit is open. The ambient temperature sensor circuit can also be diagnosed using the following Sensor Test, and Sensor Circuit Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, refer to Compass Mini-Trip Computer in the Diagnosis and Testing. For complete circuit diagrams, refer to Overhead Console in the Contents of Wiring Diagrams. Sensor Test 1. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor wire harness connector. 2. Measure the resistance of the ambient temperature sensor. At -40 °C (-40 °F), the sensor resistance is 336 kilo ohms. At -55 °C (131 °F), the sensor resistance is 2.488 kilo ohms. The sensor resistance should read between these two values. If OK, refer to Sensor Circuit Test in the Diagnosis and Testing. If not OK, replace the faulty ambient temperature sensor. Sensor Circuit Test 1. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor wire harness connector and the overhead console wire harness connector. 2. Connect a jumper wire between the two terminals in the body half of the ambient temperature sensor wire harness connector. 3. Check for continuity between the sensor return circuit and the ambient temperature sensor signal circuit cavities of the roof wire harness overhead console connector. There should be continuity. If OK, go to Step 4. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 4. Remove the jumper wire from the body half of the ambient temperature sensor wire harness connector. Check for continuity between the sensor return circuit cavity of the roof wire harness overhead console connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted sensor return circuit as required. 5. Check for continuity between the ambient temperature sensor signal circuit cavity of the roof wire harness overhead console connector and a good ground. There should be no continuity. If OK, refer to Compass Mini-Trip Computer in the Diagnosis and Testing. If not OK, repair the shorted ambient temperature sensor signal circuit as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Page 583 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Fig. 17 Ambient Temperature Sensor Remove/Install 2. Locate the ambient temperature sensor, on the right side of the radiator yoke behind the grille. 3. Disconnect the wire harness connector from the ambient temperature sensor connector receptacle. 4. Remove the one screw that secures the ambient temperature sensor bracket to the radiator yoke. 5. Remove the ambient temperature sensor from the radiator yoke. INSTALLATION 1. Position the ambient temperature sensor onto the radiator yoke. 2. Install and tighten the one screw that secures the ambient temperature sensor bracket to the radiator yoke. Tighten the screw to 5.6 Nm (50 in. lbs.) . 3. Reconnect the wire harness connector to the ambient temperature sensor connector receptacle. 4. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation Blower Motor Switch: Description and Operation BLOWER MOTOR SWITCH - FRONT The heater-A/C blower motor is controlled by a four position rotary-type blower motor switch, mounted in the heater-A/C control panel. The switch allows the selection of one of four blower motor speeds, but can only be turned OFF by selecting the OFF position with the heater-A/C mode control switch knob. The blower motor switch directs the blower motor ground path through the mode control switch to the blower motor resistor, or directly to ground through the high speed blower motor relay, as required to achieve the selected blower motor speed. The blower motor switch cannot be repaired and, if faulty or damaged, the entire heater-A/C control unit must be replaced. The blower motor switch knob is serviced separately. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation > Page 587 Blower Motor Switch: Testing and Inspection For circuit descriptions, diagrams and electrical test procedures for blower switch. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation > Page 588 Blower Motor Switch: Service and Repair REMOVAL The rear blower motor switch is integrated into the rear control and is used only on models with the optional rear heater-A/C unit. 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick or another suitable wide flat-bladed tool, gently pry above the two indentations at the outer perimeter of the rear control to release it from the headliner. 3. Pull the rear blower motor switch away from the headliner far enough to access and unplug the wire harness connector from the back of the switch. 4. Remove the rear blower motor switch from the headliner. INSTALLATION The rear blower motor switch is used only on models with the optional rear heating-A/C unit. 1. Plug the wire harness connector into the back of the rear blower motor switch. 2. Tuck the wire harness back through the rear blower motor switch mounting hole in the headliner. 3. Gently press the rear blower motor switch into the mounting hole in the headliner until it snaps into place. 4. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams Evaporator Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Diagrams High Pressure Sensor / Switch: Diagrams A/C Low Pressure Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Specifications Low Pressure Sensor / Switch: Specifications Low Pressure Cycling Switch: Hand Tighten Only ........................................................................................................................................ (n/a) (n/a) (n/a) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 599 Low Pressure Sensor / Switch: Diagrams A/C Low Pressure Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 600 Low Pressure Sensor / Switch: Description and Operation LOSS OF CHARGE SWITCH - FRONT This vehicle is equipped with a Loss of Charge Switch. This switch is screwed onto a fitting on the suction jumper line between the evaporator and the low side refrigerant system service port. The switch is used to measure if refrigerant system pressure goes too low. It is not responsible for cycling the A/C compressor clutch. The loss of charge switch is connected in series electrically with the Heater-A/C controls between ground and the Powertrain Control Module (PCM). The switch contacts open and close causing the PCM to turn the compressor clutch ON and OFF. This prevents compressor operation when the system charge is low and prevents damage to the compressor. The switch opens with a pressure of 7 to 13 psi and closes when the pressure rises to 15 to 25 psi. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 601 Low Pressure Sensor / Switch: Testing and Inspection Before performing diagnosis of the loss of charge switch, be certain that the switch is properly installed on the suction jumper line fitting. If the switch is too loose it may not open the Schrader-type valve in the accumulator fitting, which will prevent the switch from correctly monitoring the refrigerant system pressure. Remember that lower ambient temperatures during cold weather will open the switch contacts and prevent compressor operation due to the pressure/temperature relationship of the refrigerant. Also verify that the refrigerant system has the correct refrigerant charge. 1. Disconnect and isolate the battery negative cable. 2. Unplug the a/c loss of charge switch wire harness connector from the switch on the refrigerant system fitting. 3. Install a jumper wire between the two cavities of the loss of charge switch harness connector. 4. Connect a manifold gauge set to the refrigerant system service ports. 5. Connect the battery negative cable. 6. Place the heater-A/C mode control switch knob in any A/C position and start the engine. 7. Check for continuity between the two terminals of the loss of charge switch. There should be continuity with a suction pressure reading of 7 to 13 psi. If OK, test and repair the A/C switch sense circuit as required. If not OK, replace the faulty switch. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 602 Low Pressure Sensor / Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the A/C loss of charge switch switch, which is mounted to a fitting on the discharge line between the compressor and the condenser inlet. 3. Unscrew the loss of charge switch from the suction jumper line fitting. 4. Remove the loss of charge switch from the vehicle. 5. Remove the O-ring seal from the discharge line fitting and discard. INSTALLATION 1. Lubricate a new O-ring seal with clean refrigerant oil and install it on the suction jumper line fitting. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 2. Install and tighten the loss of charge switch on the suction jumper line fitting. 3. Plug the wire harness connector into the loss of charge switch. 4. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions Door Switch: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 608 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 609 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 610 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 611 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 612 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 613 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 614 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 615 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 616 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 617 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 618 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 619 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 620 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 621 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 622 Door Switch: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 623 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 624 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 625 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 626 Door Switch: Connector Views Driver Door Power Lock Motor/Ajar Switch Left Rear Door Power Lock Motor/Ajar Switch Passenger Door Power Lock Motor/Ajar Switch Right Rear Door Power Lock Motor/Ajar Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 627 Door Ajar Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 628 Door Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 629 Door Switch: Description and Operation DOOR AJAR SWITCH The door ajar switches are integral to the door latches on each door. The switches close a path to ground for the Central Timer Module (CTM) when a door is opened, and open the ground path when a door is closed. The door ajar switches cannot be repaired and, if faulty or damaged, the door latch unit must be replaced. The door ajar switches close a path to ground for the Central Timer Module (CTM) when a door is opened, and opens the ground path when a door is closed. The passenger side front door and both rear door ajar switches are connected in a parallel-series circuit between ground and the CTM, while the driver side front door ajar switch is connected in series between ground and the CTM to provide a unique input. The CTM reads the switch status through an internal pull-up, then sends the proper switch status messages to other electronic modules over the Programmable Communications Interface (PCI) data bus network. The door ajar switches can be diagnosed using conventional diagnostic tools and methods. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 630 Door Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Disconnect the door latch pigtail wire connector from the door wire harness connector. Check for continuity between the ground circuit cavity in the door wire harness connector and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the open ground circuit to ground as required. 2. Check for continuity between the ground circuit cavity and the driver or passenger door ajar switch sense circuit cavity in the door latch pigtail wire connector. There should be continuity with the door opened, and no continuity with the door closed. If OK, go to Step 3. If not OK, replace the faulty door latch unit. 3. Disconnect the body wire harness connector (Connector C2) for the Central Timer Module (CTM) from the CTM connector receptacle. Check for continuity between the driver or passenger door ajar switch sense circuit cavity of the body wire harness connector (Connector C2) and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, repair the shorted driver or passenger door ajar switch sense circuit between the door latch and the CTM as required. 4. Check for continuity between the driver or passenger door ajar switch sense circuit cavities of the body wire harness connector (Connector C2) and the door wire harness connector for the door latch. There should be continuity. If OK, use a DRB III scan tool to diagnose the CTM. Refer to the appropriate diagnostic procedures. If not OK, repair the open driver or passenger door ajar switch sense circuit between the door latch and the CTM as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations Fuel Gauge Sender: Locations Fig. 7 Fuel Gauge Sending Unit Location - Typical Module The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The fuel pump module is located inside of fuel tank. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 634 Fuel Gauge Sender: Description and Operation FUEL LEVEL SENDING UNIT / SENSOR The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation: A constant input voltage source of about 12 volts (battery voltage) is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 635 Fuel Gauge Sender: Testing and Inspection The fuel gauge sending unit contains a variable resistor (track). As the float moves up or down, electrical resistance will change. Refer to Instrument Panel and Gauges for Fuel Gauge testing. To test the gauge sending unit only, it must be removed from vehicle. The unit is part of the fuel pump module. Refer to Fuel Pump Module Removal/installation for procedures. Measure the resistance across the sending unit terminals. With float in up position, resistance should be 20 ohms ± 6%. With float in down position, resistance should be 270 ohms ± 6%. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 636 Fuel Gauge Sender: Service and Repair REMOVAL Fig. 7 Fuel Gauge Sending Unit Location - Typical Module The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module (Fig. 7). The fuel pump module is located inside of fuel tank. 1. Remove fuel tank. 2. Remove fuel pump module. 3. Unplug 4-way electrical connector (Fig. 7). 4. Disconnect 2 sending unit wires at 4-way connector. The locking collar of connector must be removed before wires can be released from connector. Note location of wires within 4-way connector. Fig. 8 Fuel Gauge Sending Unit Lock Tab/Tracks Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 637 5. The sending unit is retained to pump module with a small lock tab and notch (Fig. 8). Carefully push lock tab to the side and away from notch while sliding sending unit downward on tracks for removal. Note wire routing while removing unit from module. INSTALLATION The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module (Fig. 7). The fuel pump module is located inside of fuel tank. 1. Position sending unit into tracks. Note wire routing. 2. Push unit on tracks until lock tab snaps into notch. 3. Connect 2 sending unit wires into 4-way connector and install locking collar. 4. Connect 4-way electrical connector to module. 5. Install fuel pump module. 6. Install fuel tank. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations > Page 643 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 644 Brake Light Switch: Diagrams Brake Lamp Switch Brake Lamp Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 645 Brake Light Switch: Description and Operation The plunger type brake lamp switch is mounted on a bracket attached to the brake pedal support. CAUTION: The switch can only be adjusted during initial installation. If the switch is not adjusted properly a new switch must be installed. The primary function of the switch is to turn ON the brake lamps during braking. The switch is also used to send signals to components that must know when the brakes are applied, such as the Powertrain Control Module (PCM), which uses the signal to cancel speed control. The CAB uses the brake switch signal to monitor brake pedal application. When the switch contacts open (brakes applied), the CAB receives the brake applied signal. The CAB then monitors the RWAL system to anticipate the need for an RWAL stop. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 646 Brake Light Switch: Testing and Inspection Fig.1 Brake Lamp Switch Terminal Identification The brake lamp switch can be tested with an ohm-meter. The ohmmeter is used to check continuity between the pin terminals. Switch Circuit Identification - Terminals 1 and 2: brake lamp circuit - Terminals 3 and 4: RWAL/ABS module and Powertrain Control Module (PCM) circuit - Terminals 5 and 6: speed control circuit Switch Continuity Test NOTE: Disconnect switch harness before testing switch continuity. With switch plunger extended, attach test leads to pins 1 and 2. Replace switch if meter indicates no continuity. With switch plunger retracted, attach test leads to pins 3 and 4. Replace switch if meter indicates no continuity. With switch plunger retracted, attach test leads to pins 5 and 6. Replace switch if meter indicates no continuity. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 647 Brake Light Switch: Service and Repair Fig.2 Brake Lamp Switch & Bracket REMOVAL 1. Disconnect switch harness. 2. Press and hold brake pedal in applied position. 3. Rotate switch counterclockwise about 300 to align switch lock tab with notch in bracket. 4. Pull switch rearward out of mounting bracket and release brake pedal. INSTALLATION 1. Press and hold brake pedal down. 2. Align tab on new switch with notch in switch bracket. Then insert switch in bracket and turn it clockwise about 30 ° to lock it in place. 3. Connect harness wires to switch. 4. Release brake pedal. 5. Move the release lever on the switch to engage the switch plunger. The switch is now adjusted and can not be adjusted again. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Testing and Inspection Combination Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the multi-function switch from the switch mounting housing on the steering column. (Refer to LAMPS/LIGHTING EXTERIOR/MULTI-FUNCTION SWITCH - REMOVAL). Fig. 20 Multi-Function Switch Tests 2. Using an ohmmeter, perform the continuity and resistance tests at the terminals in the multifunction switch connector receptacle as shown in the Multi-Function Switch Tests chart. 3. If the multi-function switch fails any of the continuity or resistance tests, replace the faulty switch unit as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Testing and Inspection > Page 651 Combination Switch: Service and Repair REMOVAL WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the steering column opening cover from the instrument panel. 3. If the vehicle is so equipped, grasp the tilt steering column knob firmly and pull it straight rearward to remove it from the tilt steering column adjuster mechanism lever located on the left side of the column just below the multi-function switch control stalk. 4. From below the steering column, remove the two outboard screws that secure the upper shroud to the lower shroud. 5. Push gently inward on both sides of the upper shroud near the parting line between the upper and lower shrouds to release the snap features that secure it to the lower shroud. 6. Remove the upper shroud from the lower shroud. 7. From below the steering column, remove the one center screw that secures the lower shroud to the steering column lock housing. 8. Remove the lower shroud from the steering column. 9. Disconnect the instrument panel wire harness connector for the multi-function switch from the switch connector receptacle. Fig.16 Multi-Function Switch 10. Remove the two screws that secure the multi-function switch to the multi-function switch mounting housing. 11. Grasp the multi-function switch control stalk and pull it straight toward the outboard side of the vehicle to disengage the switch from the multi-function switch mounting housing. INSTALLATION 1. Position the multi-function switch onto the multi-function switch mounting housing. 2. Install and tighten the two screws that secure the multi-function switch to the multi-function switch mounting housing. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the instrument panel wire harness connector for the multi-function switch to the switch connector receptacle. 4. Position the lower shroud onto the steering column. 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column lock housing. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud onto the steering column. If the vehicle is equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the openings in the right side of the upper and lower shrouds. 7. Align the snap features on the upper shroud with the receptacles on the lower shroud and apply hand pressure to snap them together. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Testing and Inspection > Page 652 8. From below the steering column, install and tighten the two screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). 9. If the vehicle is so equipped, align the tilt steering column knob with the tilt steering column adjuster mechanism lever located on the left side of the column just below the multi-function switch control stalk and using hand pressure push the knob firmly onto the lever. 10. Reinstall the steering column opening cover onto the instrument panel. 11. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions Door Switch: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 657 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 658 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 659 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 660 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 661 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 662 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 663 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 664 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 665 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 666 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 667 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 668 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 669 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 670 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 671 Door Switch: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 672 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 673 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 674 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 675 Door Switch: Connector Views Driver Door Power Lock Motor/Ajar Switch Left Rear Door Power Lock Motor/Ajar Switch Passenger Door Power Lock Motor/Ajar Switch Right Rear Door Power Lock Motor/Ajar Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 676 Door Ajar Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 677 Door Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 678 Door Switch: Description and Operation DOOR AJAR SWITCH The door ajar switches are integral to the door latches on each door. The switches close a path to ground for the Central Timer Module (CTM) when a door is opened, and open the ground path when a door is closed. The door ajar switches cannot be repaired and, if faulty or damaged, the door latch unit must be replaced. The door ajar switches close a path to ground for the Central Timer Module (CTM) when a door is opened, and opens the ground path when a door is closed. The passenger side front door and both rear door ajar switches are connected in a parallel-series circuit between ground and the CTM, while the driver side front door ajar switch is connected in series between ground and the CTM to provide a unique input. The CTM reads the switch status through an internal pull-up, then sends the proper switch status messages to other electronic modules over the Programmable Communications Interface (PCI) data bus network. The door ajar switches can be diagnosed using conventional diagnostic tools and methods. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 679 Door Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Disconnect the door latch pigtail wire connector from the door wire harness connector. Check for continuity between the ground circuit cavity in the door wire harness connector and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the open ground circuit to ground as required. 2. Check for continuity between the ground circuit cavity and the driver or passenger door ajar switch sense circuit cavity in the door latch pigtail wire connector. There should be continuity with the door opened, and no continuity with the door closed. If OK, go to Step 3. If not OK, replace the faulty door latch unit. 3. Disconnect the body wire harness connector (Connector C2) for the Central Timer Module (CTM) from the CTM connector receptacle. Check for continuity between the driver or passenger door ajar switch sense circuit cavity of the body wire harness connector (Connector C2) and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, repair the shorted driver or passenger door ajar switch sense circuit between the door latch and the CTM as required. 4. Check for continuity between the driver or passenger door ajar switch sense circuit cavities of the body wire harness connector (Connector C2) and the door wire harness connector for the door latch. There should be continuity. If OK, use a DRB III scan tool to diagnose the CTM. Refer to the appropriate diagnostic procedures. If not OK, repair the open driver or passenger door ajar switch sense circuit between the door latch and the CTM as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Diagrams Glove Box Lamp And Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Diagrams > Page 683 Glove Box Lamp Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Diagrams > Page 684 Glove Box Lamp Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Open the glove box. 3. Reach through the glove box opening and behind the glove box opening upper reinforcement in the instrument panel to access and depress the retaining latches on the top and bottom of the glove box lamp and switch housing. Fig. 3 Glove Box Lamp And Switch Remove/Install 4. While holding the retaining latches depressed, push the glove box lamp and switch out through the mounting hole in the instrument panel glove box opening upper reinforcement. 5. Pull the glove box lamp and switch out from the mounting hole far enough to access the wire harness connector. 6. Disconnect the instrument panel wire harness connector from the glove box lamp and switch connector receptacle. 7. Remove the glove box lamp and switch from the instrument panel. INSTALLATION 1. Position the glove box lamp and switch to the instrument panel. 2. Reconnect the instrument panel wire harness connector to the glove box lamp and switch connector receptacle. 3. Feed the instrument panel wire harness back into the glove box lamp and switch mounting hole in the glove box opening upper reinforcement. 4. Align the glove box lamp and switch housing with the mounting hole in the instrument panel glove box opening upper reinforcement. 5. Push the glove box lamp and switch into the mounting hole in the instrument panel glove box opening upper reinforcement until the retaining latches are fully engaged. 6. Close the glove box. 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Multi-Function Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 688 Hazard Warning Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 689 Hazard Warning Switch: Description and Operation Fig.14 Multi-Function Switch MULTI-FUNCTION SWITCH The multi-function switch is secured with two screws to the multi-function switch mounting housing on the left side of the steering column, just below the steering wheel. The only visible parts of the multi-function switch are the control stalk that extends through a dedicated opening in the left side of the upper steering column shrouds, and the hazard warning switch push button that protrudes through an opening in the upper steering column shroud on the top of the steering column. The remainder of the switch, its mounting provisions, and its electrical connections are all concealed beneath the steering column shrouds. The multi-function switch control stalk has both nomenclature and International Control and Display Symbol graphics applied to it, which identify its many functions. An International Control and Display Symbol icon for "Hazard Warning" is applied to the top of the hazard warning switch push button. The switch housing and its controls are constructed of molded black plastic. A single connector receptacle connects the switch to the vehicle electrical system through a take out and connector of the instrument panel wire harness. The multi-function switch supports the following functions and features: - Continuous Wipe Modes - The control knob of the multi-function switch provides two continuous wipe switch positions, low speed or high speed. - Hazard Warning Control - The internal circuitry and hardware of the multi-function switch provide detent switching for activation and deactivation of the hazard warning system. - Headlamp Beam Selection - The internal circuitry and hardware of the multi-function switch provide detent switching for selection of the headlamp high or low beams. - Headlamp Optical Horn - The internal circuitry and hardware of the multi-function switch includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Intermittent Wipe Mode - The control knob of the multi-function switch provides an intermittent wipe mode with multiple delay interval positions. - Turn Signal Control - The internal circuitry and hardware of the multi-function switch provide both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signals. - Washer Mode - The control knob of the multi- function switch provides washer system operation when the knob is depressed towards the steering column. The multi-function switch cannot be adjusted or repaired. If any function of the switch is faulty, or if the switch is damaged, the entire switch unit must be replaced. The multi-function switch uses conventionally switched outputs and a variable resistor to control the many functions and features it provides using hard wired circuitry. The switch is grounded at all times through a single wire take out with an eyelet terminal connector of the instrument panel wire harness that is secured by a nut to a ground stud located on the left cowl side inner panel, near the left instrument panel end bracket. When the ignition switch is in the Accessory or ON positions, battery current from a fuse in the Junction Block (JB) is provided through a fused ignition switch output (run acc) circuit. Following are descriptions of how the multi-function switch operates to control the many functions and features it provides: Continuous Wipe Modes - When the control knob of the multi-function switch is rotated to the High or Low positions, the circuitry within the Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 690 switch provides a battery current output directly to the high or low speed brush of the wiper motor. When the control knob is in the OFF position, the circuitry within the switch connects the output of the wiper motor park switch to the low speed brush of the wiper motor. - Hazard Warning Control - The hazard warning push button is pushed down to unlatch the switch and activate the hazard warning system, and pushed down again to latch the switch and turn the system OFF. When the hazard warning switch is latched (hazard warning OFF), the push button will be in a lowered position on the top of the steering column shroud; and, when the hazard warning switch is unlatched (hazard warning ON), the push button will be in a raised position. The multi-function switch hazard warning circuitry provides a signal to the hazard warning sense of the combination flasher to activate or deactivate the flasher output to the hazard warning lamps. - Headlamp Beam Selection - The multi-function switch control stalk is pulled towards the steering wheel past a detent, then released to actuate the headlamp beam selection switch. Each time the control stalk is actuated in this manner, the opposite headlamp mode from what is currently selected will be activated. The internal circuitry of the headlamp beam selection switch directs a ground signal output from the headlamp switch to the appropriate low beam or high beam sense of the Central Timer Module (CTM). The CTM then controls a hard wired output to activate the selected headlamp beams. - Headlamp Optical Horn - The left multi-function switch control stalk is pulled towards the steering wheel to just before a detent, to momentarily activate the headlamp high beams. The high beams will remain illuminated until the control stalk is released. The internal circuitry of the headlamp beam selection switch provides a momentary ground path to the CTM high beam sense. - Intermittent Wipe Mode - When the multi-function switch control knob is rotated to the Delay position, the circuitry within the switch provides a battery current signal to the Central Timer Module (CTM). If the Delay mode is selected, the control knob can then be rotated to multiple minor detent positions, which actuates a variable resistor within the switch and provides a hard wired output to the CTM that signals the desired delay interval for the intermittent wiper feature. - Turn Signal Control - The multi-function switch control stalk actuates the turn signal switch. When the control stalk is moved in the upward direction, the right turn signal circuitry is activated; and, when the control stalk is moved in the downward direction, the left turn signal circuitry is activated. The multi-function switch turn signal circuitry provides a signal to the right or left turn signal sense of the combination flasher to activate or deactivate the flasher output to the proper turn signal lamps. The turn signal switch has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that provides turn signals only until the multi-function switch control stalk is released. When the control stalk is moved to a turn signal switch detent position, the cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clock-spring mechanism rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. In other words, if the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. - Washer Mode - Pushing the control knob on the end of the multi-function switch control stalk towards the steering column provides a battery current output through the momentary single pole, single throw washer switch circuitry to provide a washer signal input to the CTM. The CTM then provides a battery current output to operate the washer pump/motor. If the wipers are not operating when the washer switch is actuated, the CTM will operate the wiper motor for as long as the washer switch is depressed plus about three additional wipe cycles. If the wipers are operating in the intermittent mode when the washer switch is actuated, the CTM will operate the wiper motor at a fixed low speed for as long as the washer switch is depressed plus about three additional wipe cycles before the wipers return to the selected intermittent wipe interval. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations The headlamp switch is located in the instrument panel, outboard of the steering column. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 694 Headlamp Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 695 Headlamp Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 696 Headlamp Switch: Description and Operation The headlamp switch is located in the instrument panel, outboard of the steering column. It closes a path to ground for the Central Timer Module (CTM) when the park or head lamps are ON and the driver door ajar switch is closed (driver door is open). The headlamp switch opens the ground path when the headlamp switch is turned OFF. The ground path is also opened when the driver door ajar switch is open (driver door is closed). This switch also contains a rheostat for controlling the illumination level of the instrument cluster lamps. The headlamp switch cannot be repaired and, if faulty or damaged, it must be replaced. The headlamp switch has an OFF position, a parking lamp position, and a headlamp ON position. High beams are controlled by the multifunction switch on the steering column. The headlamp switch cannot be repaired. It must be replaced. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 697 Headlamp Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the headlamp switch. (Refer to HEADLAMP SWITCH - REMOVAL). Headlamp Switch Continuity Table Fig. 14 Headlamp Switch 2. Using an ohmmeter, test for continuity between the terminals of the switch as shown in the Headlamp Switch Continuity table. 3. If test results are not obtained as shown in the Headlamp Switch Continuity table, replace the headlamp switch. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 698 Headlamp Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel from the instrument panel. 3. Disconnect the wire harness connector from the headlamp switch. 4. Remove the headlamp switch from the cluster bezel. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the headlamp switch to the cluster bezel. 2. Install and tighten the screws that secure the headlamp switch. Tighten the screws to 2.2 Nm (20 in. lbs.). 3. Reconnect the wire harness to the headlamp switch. 4. Install the cluster bezel onto the instrument panel. 5. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service Precautions Horn Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service Precautions > Page 702 Horn Switch: Description and Operation Fig. 3 Driver Side Airbag Module Trim Cover And Horn Switch A center-blow, normally open, resistive membrane-type horn switch is secured with heat stakes to the back side of the driver side airbag module trim cover in the center of the steering wheel . The switch consists of two plastic membranes, one that is flat and one that is slightly convex. These two membranes are secured to each other around the perimeter. Inside the switch, the centers of the facing surfaces of these membranes each has a grid made with an electrically conductive material applied to it. One of the grids is connected to a circuit that provides it with continuity to ground at all times. The grid of the other membrane is connected to the horn relay control circuit. The steering wheel and steering column must be properly grounded in order for the horn switch to function properly. The horn switch is only serviced as a part of the driver side airbag module trim cover. If the horn switch is damaged or faulty, or if the driver side airbag is deployed, the driver side airbag module trim cover and horn switch must be replaced as a unit. When the center area of the driver side airbag trim cover is depressed, the electrically conductive grids on the facing surfaces of the horn switch membranes contact each other, closing the switch circuit. The completed horn switch circuit provides a ground for the control coil side of the horn relay, which activates the relay. When the horn switch is released, the resistive tension of the convex membrane separates the two electrically conductive grids and opens the switch circuit. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service Precautions > Page 703 Horn Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Remove the steering column opening cover from the instrument panel. 2. Check for continuity between the metal steering column jacket and a good ground. There should be continuity. If OK, go to Step 3. 3. Remove the driver side airbag module from the steering wheel. Disconnect the horn switch wire harness connectors from the driver side airbag module. 4. Remove the horn relay from the Junction Block (JB). Check for continuity between the steering column half of the horn switch feed wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted horn relay control circuit to the horn relay in the JB as required. 5. Check for continuity between the steering column half of the horn switch feed wire harness connector and the horn relay control circuit cavity for the horn relay in the JB. There should be continuity. If OK, go to Step 6. If not OK, repair the open horn relay control circuit to the horn relay in the JB as required. 6. Check for continuity between the horn switch feed wire and the horn switch ground wire on the driver side airbag module. There should be no continuity. If OK, go to Step 7. If not OK, replace the faulty horn switch. 7. Depress the center of the driver side airbag module trim cover and check for continuity between the horn switch feed wire and the horn switch ground wire on the driver side airbag module. There should now be continuity. If not OK, replace the faulty horn switch. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Multi-Function Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 707 Turn Signal Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 708 Turn Signal Switch: Description and Operation Fig.14 Multi-Function Switch MULTI-FUNCTION SWITCH The multi-function switch is secured with two screws to the multi-function switch mounting housing on the left side of the steering column, just below the steering wheel. The only visible parts of the multi-function switch are the control stalk that extends through a dedicated opening in the left side of the upper steering column shrouds, and the hazard warning switch push button that protrudes through an opening in the upper steering column shroud on the top of the steering column. The remainder of the switch, its mounting provisions, and its electrical connections are all concealed beneath the steering column shrouds. The multi-function switch control stalk has both nomenclature and International Control and Display Symbol graphics applied to it, which identify its many functions. An International Control and Display Symbol icon for "Hazard Warning" is applied to the top of the hazard warning switch push button. The switch housing and its controls are constructed of molded black plastic. A single connector receptacle connects the switch to the vehicle electrical system through a take out and connector of the instrument panel wire harness. The multi-function switch supports the following functions and features: - Continuous Wipe Modes - The control knob of the multi-function switch provides two continuous wipe switch positions, low speed or high speed. - Hazard Warning Control - The internal circuitry and hardware of the multi-function switch provide detent switching for activation and deactivation of the hazard warning system. - Headlamp Beam Selection - The internal circuitry and hardware of the multi-function switch provide detent switching for selection of the headlamp high or low beams. - Headlamp Optical Horn - The internal circuitry and hardware of the multi-function switch includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Intermittent Wipe Mode - The control knob of the multi-function switch provides an intermittent wipe mode with multiple delay interval positions. - Turn Signal Control - The internal circuitry and hardware of the multi-function switch provide both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signals. - Washer Mode - The control knob of the multi- function switch provides washer system operation when the knob is depressed towards the steering column. The multi-function switch cannot be adjusted or repaired. If any function of the switch is faulty, or if the switch is damaged, the entire switch unit must be replaced. The multi-function switch uses conventionally switched outputs and a variable resistor to control the many functions and features it provides using hard wired circuitry. The switch is grounded at all times through a single wire take out with an eyelet terminal connector of the instrument panel wire harness that is secured by a nut to a ground stud located on the left cowl side inner panel, near the left instrument panel end bracket. When the ignition switch is in the Accessory or ON positions, battery current from a fuse in the Junction Block (JB) is provided through a fused ignition switch output (run acc) circuit. Following are descriptions of how the multi-function switch operates to control the many functions and features it provides: Continuous Wipe Modes - When the control knob of the multi-function switch is rotated to the High or Low positions, the circuitry within the Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 709 switch provides a battery current output directly to the high or low speed brush of the wiper motor. When the control knob is in the OFF position, the circuitry within the switch connects the output of the wiper motor park switch to the low speed brush of the wiper motor. - Hazard Warning Control - The hazard warning push button is pushed down to unlatch the switch and activate the hazard warning system, and pushed down again to latch the switch and turn the system OFF. When the hazard warning switch is latched (hazard warning OFF), the push button will be in a lowered position on the top of the steering column shroud; and, when the hazard warning switch is unlatched (hazard warning ON), the push button will be in a raised position. The multi-function switch hazard warning circuitry provides a signal to the hazard warning sense of the combination flasher to activate or deactivate the flasher output to the hazard warning lamps. - Headlamp Beam Selection - The multi-function switch control stalk is pulled towards the steering wheel past a detent, then released to actuate the headlamp beam selection switch. Each time the control stalk is actuated in this manner, the opposite headlamp mode from what is currently selected will be activated. The internal circuitry of the headlamp beam selection switch directs a ground signal output from the headlamp switch to the appropriate low beam or high beam sense of the Central Timer Module (CTM). The CTM then controls a hard wired output to activate the selected headlamp beams. - Headlamp Optical Horn - The left multi-function switch control stalk is pulled towards the steering wheel to just before a detent, to momentarily activate the headlamp high beams. The high beams will remain illuminated until the control stalk is released. The internal circuitry of the headlamp beam selection switch provides a momentary ground path to the CTM high beam sense. - Intermittent Wipe Mode - When the multi-function switch control knob is rotated to the Delay position, the circuitry within the switch provides a battery current signal to the Central Timer Module (CTM). If the Delay mode is selected, the control knob can then be rotated to multiple minor detent positions, which actuates a variable resistor within the switch and provides a hard wired output to the CTM that signals the desired delay interval for the intermittent wiper feature. - Turn Signal Control - The multi-function switch control stalk actuates the turn signal switch. When the control stalk is moved in the upward direction, the right turn signal circuitry is activated; and, when the control stalk is moved in the downward direction, the left turn signal circuitry is activated. The multi-function switch turn signal circuitry provides a signal to the right or left turn signal sense of the combination flasher to activate or deactivate the flasher output to the proper turn signal lamps. The turn signal switch has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that provides turn signals only until the multi-function switch control stalk is released. When the control stalk is moved to a turn signal switch detent position, the cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clock-spring mechanism rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. In other words, if the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. - Washer Mode - Pushing the control knob on the end of the multi-function switch control stalk towards the steering column provides a battery current output through the momentary single pole, single throw washer switch circuitry to provide a washer signal input to the CTM. The CTM then provides a battery current output to operate the washer pump/motor. If the wipers are not operating when the washer switch is actuated, the CTM will operate the wiper motor for as long as the washer switch is depressed plus about three additional wipe cycles. If the wipers are operating in the intermittent mode when the washer switch is actuated, the CTM will operate the wiper motor at a fixed low speed for as long as the washer switch is depressed plus about three additional wipe cycles before the wipers return to the selected intermittent wipe interval. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Fig. 1 Battery Temperature Sensor Location The battery temperature sensor is located under vehicle battery and is attached to a mounting hole on battery tray. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 715 Battery Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 716 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and 02 sensor heater tests). Most OBD II monitors are disabled below 20 degrees F. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 717 Battery Temperature Sensor: Testing and Inspection Tests 1 - 2 SYMPTOM CHECKING THE AMBIENT/BATTERY TEMPERATURE SENSOR POSSIBLE CAUSES - Ambient/Battery temperature sensor - Ambient/Battery temperature sensor (Out Of Calibration) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 718 Battery Temperature Sensor: Service and Repair Fig. 1 Battery Temperature Sensor Location REMOVAL The battery temperature sensor is located under vehicle battery (Fig. 1) and is attached to a mounting hole on battery tray. 1. Remove battery. Refer to Battery for procedures. 2. Disconnect sensor pigtail harness from engine wire harness. Sensor pigtail harness is clipped to vehicle near its electrical connector. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION The battery temperature sensor is located under vehicle battery (Fig. 1) and is attached to a mounting hole on battery tray. 1. Feed pigtail harness through hole in top of battery tray and press sensor into top of battery tray. 2. Connect pigtail harness. 3. Install battery. Refer to Battery for procedures. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Brake Pressure Switch > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor ................................................................................................................... ................................................... 12 Nm (106 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 725 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 726 Camshaft Position Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 727 Camshaft Position Sensor: Description and Operation Fig. 4 CMP Location The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. Fig. 5 CMP Sensor And Tonewheel The CMP sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects notches located on a tonewheel. The tonewheel is located at the front of the camshaft for the right cylinder head. As the tonewheel rotates, the notches pass through the sync signal generator. The pattern of the notches (viewed counter-clockwise from front of engine) is: 1 notch, 2 notches, 3 notches, 3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 728 notches, 2 notches 1 notch, 3 notches and 1 notch. The signal from the CMP sensor 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 729 Camshaft Position Sensor: Service and Repair Fig. 7 CMP Location REMOVAL The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. It is easier to remove/install sensor from under vehicle. 1. Raise and support vehicle. 2. Disconnect electrical connector at CMP sensor. 3. Remove sensor mounting bolt. 4. Carefully pry sensor from cylinder head in a rocking action with two small screwdrivers. 5. Check condition of sensor O-ring. INSTALLATION The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. 1. Clean out machined hole in cylinder head. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into cylinder head with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder head. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in. lbs.) torque. 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications Engine Coolant Temperature (ECT) Sensor: Specifications Engine Coolant Temperature Sensor ....................................................................................................................................................... 11 Nm (96 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 733 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 734 Engine Coolant Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 735 Engine Coolant Temperature (ECT) Sensor: Description and Operation DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: ^ for engine coolant temperature gauge operation through CCD or PCI (J1850) ^ Communications ^ Injector pulse-width ^ Spark-advance curves ^ ASD relay shut-down times ^ Idle Air Control (IAC) motor key-on steps ^ Pulse-width prime-shot during cranking ^ 02 sensor closed loop times ^ Purge solenoid on/off times ^ EGR solenoid on/off times (if equipped) ^ Leak Detection Pump operation (if equipped) ^ Radiator fan relay on/off times (if equipped) ^ Target idle speed Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 736 Engine Coolant Temperature (ECT) Sensor: Service and Repair REMOVAL - 4.7L WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. The ECT sensor is located near the front of the intake manifold. 1. Partially drain cooling system. 2. Disconnect electrical connector from ECT sensor. 3. Remove sensor from intake manifold. INSTALLATION - 4.7L 1. Install sensor. 2. Tighten to 11 Nm (8 ft. lbs.) torque. 3. Connect electrical connector to sensor. 4. Replace any lost engine coolant. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt .............................................................................................................................................................. 28 Nm (21 Ft. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 740 Crankshaft Position Sensor: Locations Fig. 15 CKP Sensor Location The Crankshaft Position (CKP) sensor is located at the right-rear side of the engine cylinder block. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 741 Crankshaft Position Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 742 Crankshaft Position Sensor: Description and Operation Fig. 15 CKP Sensor Location The Crankshaft Position Sensor (CKP) is mounted into the right-rear side of the engine block. 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. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. Fig. 17 CKP Sensor Operation And Tonewheel Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 743 On this engine, a tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 744 Crankshaft Position Sensor: Service and Repair Fig. 19 CKP Sensor Location/Removal/Installation REMOVAL The Crankshaft Position (CKP) sensor is located at the right-rear side of the engine cylinder block. It is positioned and bolted into a machined hole in the engine block. 1. Disconnect CKP electrical connector at sensor. 2. Remove CKP mounting bolt. 3. Carefully pry sensor from cylinder block in a rocking action with two small screwdrivers. 4. Remove sensor from vehicle. 5. Check condition of sensor O-ring. INSTALLATION 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into engine block with a slight rocking action. Do not twist sensor into position as damage to O-ring may result CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 28 Nm (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations Fig. 7 Fuel Gauge Sending Unit Location - Typical Module The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module. The fuel pump module is located inside of fuel tank. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 748 Fuel Level Sensor: Description and Operation FUEL LEVEL SENDING UNIT / SENSOR The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation: A constant input voltage source of about 12 volts (battery voltage) is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 749 Fuel Level Sensor: Service and Repair REMOVAL Fig. 7 Fuel Gauge Sending Unit Location - Typical Module The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module. The fuel pump module is located inside of fuel tank. 1. Remove fuel tank. 2. Remove fuel pump module. 3. Unplug 4-way electrical connector. 4. Disconnect 2 sending unit wires at 4-way connector. The locking collar of connector must be removed before wires can be released from connector. Note location of wires within 4-way connector. Fig. 8 Fuel Gauge Sending Unit Lock Tab/Tracks Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 750 5. The sending unit is retained to pump module with a small lock tab and notch. Carefully push lock tab to the side and away from notch while sliding sending unit downward on tracks for removal. Note wire routing while removing unit from module. INSTALLATION The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module. The fuel pump module is located inside of fuel tank. 1. Position sending unit into tracks. Note wire routing. 2. Push unit on tracks until lock tab snaps into notch. 3. Connect 2 sending unit wires into 4-way connector and install locking collar. 4. Connect 4-way electrical connector to module. 5. Install fuel pump module. 6. Install fuel tank. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications Intake Air Temperature (IAT) Sensor: Specifications Intake Manifold Air TEMP. Sensor ........................................................................................................................................................ 28 Nm (20 Ft. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 754 Intake Air Temperature (IAT) Sensor: Locations Fig. 24 Intake Manifold Air Sensor Location The Intake Manifold Air Temperature (IAT) sensor is installed into the intake manifold plenum near the left side of the throttle body. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 755 Intake Air Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 756 Intake Air Temperature (IAT) Sensor: Description and Operation The 2-wire Intake Manifold Air Temperature (IAT) sensor is installed in the intake manifold with the sensor element extending into the air stream. The IAT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as intake manifold temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. The IAT sensor provides an input voltage to the Powertrain Control Module (PCM) indicating the density of the air entering the intake manifold based upon intake manifold temperature. At key-ON, a 5-volt power circuit is supplied to the sensor from the PCM. The sensor is grounded at the PCM through a low-noise, sensor-return circuit. The PCM uses this input to calculate the following: - Injector pulse-width - Adjustment of spark timing (to help prevent spark knock with high intake manifold air-charge temperatures) The resistance values of the IAT sensor is the same as for the Engine Coolant Temperature (ECT) sensor. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 757 Intake Air Temperature (IAT) Sensor: Service and Repair Fig. 24 Intake Manifold Air Sensor Location REMOVAL The Intake Manifold Air Temperature (IAT) sensor is installed into the intake manifold plenum near the left side of the throttle body. 1. Disconnect electrical connector from sensor. 2. Remove sensor from intake manifold. INSTALLATION 1. Install sensor into intake manifold. Tighten sensor to 28 Nm (20 ft. lbs.) torque. 2. Connect electrical connector to sensor. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications Manifold Absolute Pressure (MAP) Sensor: Specifications MAP Sensor Mounting Screws ............................................................................................................ ..................................................... 3 Nm (25 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 761 Manifold Absolute Pressure (MAP) Sensor: Locations Fig. 27 MAP And ECT Sensor Locations The MAP sensor is located on the front of the intake manifold. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 762 Manifold Absolute Pressure Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 763 Manifold Absolute Pressure (MAP) Sensor: Description and Operation The MAP sensor is located on the front of the intake manifold. An O-ring seals the sensor to the intake manifold. The MAP sensor is used as an input to the Powertrain Control Module (PCM). It contains a silicon based sensing unit to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When manifold absolute pressure (MAP) equals Barometric pressure, the pulse width will be at maximum. A 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5V and full scale is 4.5V. For a pressure swing of 0-15 psi, the voltage changes 4.0V To operate the sensor, it is supplied a regulated 4.8 to 5.1 volts. Ground is provided through the low-noise, sensor return circuit at the PCM. The MAP sensor input is the number one contributor to fuel injector pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or at a higher altitude, because the air density changes with altitude. It will also help to correct for varying barometric pressure. Barometric pressure and altitude have a direct inverse correlation; as altitude goes up, barometric goes down. At key-ON, the PCM powers up and looks at MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure (relative to altitude). Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key-on. The difference between current voltage and what it was at key-on, is manifold vacuum. During key-ON (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring a known good sensor. As the altitude increases, the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key-ON, the barometric pressure needs to be updated. Any time the PCM sees Wide Open Throttle (WOT), based upon Throttle Position Sensor (TPS) angle and RPM, it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor input to aid in calculating the following: - Manifold pressure - Barometric pressure - Engine load - Injector pulse-width - Spark-advance programs - Shift-point strategies (certain automatic transmissions only) - Idle speed - Decel fuel shutoff The MAP sensor signal is provided from a single piezoresistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As manifold pressure changes, the diaphragm moves causing the element to deflect, which stresses the silicone. When silicone is exposed to stress, its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally. The sensor also contains electronics that condition the signal and provide temperature compensation. The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; meaning as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg. Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is approximately 29.92 in Hg. For every 100 feet of altitude, barometric pressure drops 0.10 in. Hg. If a storm goes through it can change barometric pressure from what should be present for that altitude. You should know what the average pressure and corresponding barometric pressure is for your area. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 764 Manifold Absolute Pressure (MAP) Sensor: Service and Repair Fig. 27 MAP And ECT Sensor Locations REMOVAL The MAP sensor is located on the front of the intake manifold. An O-ring seals the sensor to the intake manifold. 1. Disconnect electrical connector at sensor. 2. Clean area around MAP sensor. 3. Remove 2 sensor mounting bolts. 4. Remove MAP sensor from intake manifold. INSTALLATION The MAP sensor is located on the front of the intake manifold. An O-ring seals the sensor to the intake manifold. 1. Clean MAP sensor mounting hole at intake manifold. 2. Check MAP sensor O-ring seal for cuts or tears. 3. Position sensor into manifold. 4. Install MAP sensor mounting bolts (screws). Tighten screws to 3 Nm (25 In. lbs.) torque. 5. Connect electrical connector. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams Engine Oil Pressure Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 768 Oil Pressure Sensor: Description and Operation DESCRIPTION The 2-wire, electrical/mechanical engine oil pressure sensor (sending unit) is located in an engine oil pressure gallery. OPERATION The oil pressure sensor uses two circuits. They are: ^ A signal to the PCM relating to engine oil pressure ^ A sensor ground through the PCM's sensor return The oil pressure sensor returns a voltage signal back to the PCM relating to engine oil pressure. This signal is then transferred (bussed) to the instrument panel on a CCD bus circuit to operate the oil pressure gauge and the check gauges lamp. Ground for the sensor is provided by the PCM through a low noise sensor return. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 769 Oil Pressure Sensor: Service and Repair REMOVAL 1. Disconnect the negative cable from the battery. 2. Raise vehicle on hoist. 3. Remove front splash shield. 4. Disconnect oil pressure sender wire (Fig. 107). 5. Remove the pressure sender (Fig. 107). INSTALLATION 1. Install oil pressure sender. 2. Connect oil pressure sender wire. 3. Install front splash shield. 4. Lower vehicle. 5. Connect the negative battery cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Oxygen Sensor .................................................................................................................................... .................................................... 30 Nm (22 Ft. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System Oxygen Sensor: Locations Engine Compartment/Exhaust System The upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. The right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System > Page 775 Oxygen Sensor: Locations OBD-II Heated Oxygen Sensor Numbering Convention - Cylinder bank number one is the bank that contains number one cylinder. See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 776 Oxygen Sensor: Diagrams Oxygen Sensor 1/1 Upstream (California) Oxygen Sensor 1/2 Downstream (California) Oxygen Sensor 1/2 Downstream (Except California) Oxygen Sensor 2/1 Upstream (California) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 777 Oxygen Sensor 2/2 Downstream (California) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 778 Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 779 Oxygen Sensor Downstream Heater Relay (California) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 780 Oxygen Sensor: Service Precautions WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Application O(2) Sensor Configuration Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Application > Page 783 Oxygen Sensor: Application and ID OBD-II Heated Oxygen Sensor Numbering Convention - Cylinder bank number one is the bank that contains number one cylinder. See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 784 Oxygen Sensor: Description and Operation The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Depending on the emission package, the vehicle may use a total of either 2 or 4 sensors. NAA Emissions Package: Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2). With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. NAS or NAE Emissions Package: On this emissions package, 4 sensors are used: 2 upstream (referred to as 1/1 and 2/1) and 2 downstream (referred to as 1/2 and 2/2). With this emission package, the right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. An O2 sensor is a galvanic battery that provides the PCM with a voltage signal (0-1 volt) inversely proportional to the amount of oxygen in the exhaust. In other words, if the oxygen content is low, the voltage output is high; if the oxygen content is high the output voltage is low. The PCM uses this information to adjust injector pulse-width to achieve the 14.7-to-1 air/fuel ratio necessary for proper engine operation and to control emissions. The O2 sensor must have a source of oxygen from outside of the exhaust stream for comparison. Current O2 sensors receive their fresh oxygen (outside air) supply through the wire harness. This is why it is important to never solder an O2 sensor connector, or pack the connector with grease. Four wires (circuits) are used on each O2 sensor: a 12-volt feed circuit for the sensor heating element; a ground circuit for the heater element; a low-noise sensor return circuit to the PCM, and an input circuit from the sensor back to the PCM to detect sensor operation. Oxygen Sensor Heater Relay: If the vehicle is equipped with 4 oxygen sensors, a separate oxygen sensor relay is used to supply voltage to the sensor heating elements. This particular relay is used only for the 1/2 and 2/2 downstream sensors. Voltage for the other 2 sensor heating elements is supplied directly from the ASD relay. To avoid the large simultaneous current surge needed to operate all 4 sensors, power is delayed to the 2 downstream heater elements by the PCM for approximately 2 seconds. Oxygen Sensor Heater Elements: The O2 sensor uses a Positive Thermal Co-efficient (PTC) heater element. As temperature increases, resistance increases. At ambient temperatures around 70 °F, the resistance of the heating element is approximately 13.5 ohms on the this engine. As the sensor's temperature increases, resistance in the heater element increases. This allows the heater to maintain the optimum operating temperature of approximately 930 ° - 1100 °F (500 ° - 600 °C). Although the sensors operate the same, there are physical differences, due to the environment that they operate in, that keep them from being interchangeable. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation, the PCM monitors certain O2 sensor input(s) along with other inputs, and adjusts the injector pulse width accordingly. During Open Loop operation, the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. Upstream Sensor - Engine Equipped With 2 Sensors: The upstream sensor (1/1) provides an input voltage to the PCM. The input tells the PCM the oxygen content of the exhaust gas. The PCM uses this information to fine tune fuel delivery to maintain the correct oxygen content at the downstream oxygen sensor. The PCM will change the air/fuel ratio until the upstream sensor inputs a voltage that the PCM has determined will make the downstream sensor output (oxygen content) correct. The upstream oxygen sensor also provides an input to determine catalytic convertor efficiency. Downstream Sensor - Engine Equipped With 2 Sensors: The downstream oxygen sensor (1/2) is also used to determine the correct air-fuel ratio. As the oxygen content changes at the downstream sensor, the PCM calculates how much air-fuel ratio change is required. The PCM then looks at the upstream oxygen sensor voltage and changes fuel delivery until the upstream sensor voltage changes enough to correct the downstream sensor voltage (oxygen content). The downstream oxygen sensor also provides an input to determine catalytic convertor efficiency. Upstream Sensors - Engine Equipped With 4 Sensors: Two upstream sensors are used (1/1 and 2/1). The 1/1 sensor is the first sensor to receive exhaust gases from the # 1 cylinder. They provide an input voltage to the PCM. The input tells the PCM the oxygen content of the exhaust gas. The PCM uses this information to fine tune fuel delivery to maintain the correct oxygen content at the downstream oxygen sensors. The PCM will change the air/fuel ratio until the upstream sensors input a voltage that the PCM has determined will make the downstream sensors output (oxygen content) correct. The upstream oxygen sensors also provide an input to determine mini-catalyst efficiency. Main catalytic convertor efficiency is not calculated with this package. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 785 Downstream Sensors - Engine Equipped With 4 Sensors: Two downstream sensors are used (1/2 and 2/2). The downstream sensors are used to determine the correct air-fuel ratio. As the oxygen content changes at the downstream sensor, the PCM calculates how much air-fuel ratio change is required. The PCM then looks at the upstream oxygen sensor voltage, and changes fuel delivery until the upstream sensor voltage changes enough to correct the downstream sensor voltage (oxygen content). The downstream oxygen sensors also provide an input to determine mini-catalyst efficiency. Main catalytic convertor efficiency is not calculated with this package. Engines equipped with either a downstream sensor(s), or a post-catalytic sensor, will monitor catalytic convertor efficiency. If efficiency is below emission standards, the Malfunction Indicator Lamp (MIL) will be illuminated and a Diagnostic Trouble Code (DTC) will be set. Refer to Monitored Systems in Emission Control Systems for additional information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 786 Oxygen Sensor: Service and Repair REMOVAL Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. For sensor operation, it must have a comparison source of oxygen from outside the exhaust system. This fresh air is supplied to the sensor through its pigtail wiring harness. Fig. 28 Upstream Oxygen Sensor Locations Fig. 29 Downstream Oxygen Sensor Location Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 787 Fig. 30 Pre-Catalyst/Post-Catalyst Oxygen Sensor Locations Fig. 31 Left/Right Oxygen Sensor Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 788 Fig. 32 Oxygen Sensor Locations 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 O2S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove the O2S sensor with an oxygen sensor removal and installation tool. 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 O2S sensor. Tighten to 30 Nm (22 ft. lbs.) torque. 2. Connect the O2S sensor wire connector. 3. Lower the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications Power Steering Pressure Switch: Specifications Power Steering Pressure Switch ............................................................................................................................................... 14-22 Nm (124-195 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 792 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 793 Power Steering Pressure Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 794 Power Steering Pressure Switch: Description and Operation DESCRIPTION A pressure sensing switch is included in the power steering system (mounted on the high pressure line). This switch will be used only on vehicles equipped with a 4.7L V-8 engine and power steering. OPERATION The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high pump load and low engine rpm; such as during parking maneuvers. The PCM will then increase the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load. When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the normally closed switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling. When pump pressure drops to approximately 1379 kPa (200 psi), the switch circuit will re-close and engine idle speed will return to its previous setting. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 795 Power Steering Pressure Switch: Service and Repair REMOVAL The power steering pressure switch is installed in the power steering high-pressure hose. 1. Disconnect electrical connector from power steering pressure switch. 2. Place a small container or shop towel beneath switch to collect any excess fluid. 3. Remove switch. Use back-up wrench on power steering line to prevent line bending. INSTALLATION This switch is used only with 4.7L V-8 engine. 1. Install power steering switch into power steering line. 2. Tighten to 14-22 Nm (124-195 inch lbs.) torque. 3. Connect electrical connector to switch. 4. Check power steering fluid and add as necessary. 5. Start engine and again check power steering fluid. Add fluid if necessary. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Mounting Screws ............................................................................................................................................... 7 Nm (60 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 799 Throttle Position Sensor: Locations The TPS is located on the throttle body. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 800 Throttle Position Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 801 Throttle Position Sensor: Description and Operation The 3-wire Throttle Position Sensor (TPS) is mounted on the throttle body and is connected to the throttle blade. The TPS is a 3-wire variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance (output voltage) of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from 0.26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: - Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - OFF-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 802 Throttle Position Sensor: Service and Repair REMOVAL The TPS is located on the throttle body. 1. Remove air duct and air resonator box at throttle body. Fig. 35 Throttle Body, Sensor And Electrical Connectors 2. Disconnect TPS electrical connector. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 803 Fig. 41 TPS Mounting Bolts 3. Remove two TPS mounting bolts (screws). 4. Remove TPS from throttle body. Fig. 43 TPS Installation Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 804 INSTALLATION The throttle shaft end of throttle body slides into a socket in TPS. The TPS must be installed so that it can be rotated a few degrees. If sensor will not rotate, install sensor with throttle shaft on other side of socket tangs. The TPS will be under slight tension when rotated. 1. Install TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 In. lbs.) torque. 3. Manually operate throttle control lever by hand to check for any binding of TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct/air box to throttle body. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Transmission Position Switch/Sensor: Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 808 Transmission Position Switch/Sensor: Description and Operation DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has six switch contacts that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. - Supply ground to the TCM for backup lamp control in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 814 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 815 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 816 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 817 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 818 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 819 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 820 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 821 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 822 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 823 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 824 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 825 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 826 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 827 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 828 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 829 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 830 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 831 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Mounting Screws ............................................................................................................................................... 7 Nm (60 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 836 Throttle Position Sensor: Locations The TPS is located on the throttle body. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 837 Throttle Position Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 838 Throttle Position Sensor: Description and Operation The 3-wire Throttle Position Sensor (TPS) is mounted on the throttle body and is connected to the throttle blade. The TPS is a 3-wire variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance (output voltage) of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from 0.26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: - Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - OFF-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 839 Throttle Position Sensor: Service and Repair REMOVAL The TPS is located on the throttle body. 1. Remove air duct and air resonator box at throttle body. Fig. 35 Throttle Body, Sensor And Electrical Connectors 2. Disconnect TPS electrical connector. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 840 Fig. 41 TPS Mounting Bolts 3. Remove two TPS mounting bolts (screws). 4. Remove TPS from throttle body. Fig. 43 TPS Installation Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 841 INSTALLATION The throttle shaft end of throttle body slides into a socket in TPS. The TPS must be installed so that it can be rotated a few degrees. If sensor will not rotate, install sensor with throttle shaft on other side of socket tangs. The TPS will be under slight tension when rotated. 1. Install TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 In. lbs.) torque. 3. Manually operate throttle control lever by hand to check for any binding of TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct/air box to throttle body. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor ................................................................................................................... ................................................... 12 Nm (106 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 846 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 847 Camshaft Position Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 848 Camshaft Position Sensor: Description and Operation Fig. 4 CMP Location The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. Fig. 5 CMP Sensor And Tonewheel The CMP sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects notches located on a tonewheel. The tonewheel is located at the front of the camshaft for the right cylinder head. As the tonewheel rotates, the notches pass through the sync signal generator. The pattern of the notches (viewed counter-clockwise from front of engine) is: 1 notch, 2 notches, 3 notches, 3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 849 notches, 2 notches 1 notch, 3 notches and 1 notch. The signal from the CMP sensor 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 850 Camshaft Position Sensor: Service and Repair Fig. 7 CMP Location REMOVAL The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. It is easier to remove/install sensor from under vehicle. 1. Raise and support vehicle. 2. Disconnect electrical connector at CMP sensor. 3. Remove sensor mounting bolt. 4. Carefully pry sensor from cylinder head in a rocking action with two small screwdrivers. 5. Check condition of sensor O-ring. INSTALLATION The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. 1. Clean out machined hole in cylinder head. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into cylinder head with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder head. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in. lbs.) torque. 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt .............................................................................................................................................................. 28 Nm (21 Ft. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 854 Crankshaft Position Sensor: Locations Fig. 15 CKP Sensor Location The Crankshaft Position (CKP) sensor is located at the right-rear side of the engine cylinder block. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 855 Crankshaft Position Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 856 Crankshaft Position Sensor: Description and Operation Fig. 15 CKP Sensor Location The Crankshaft Position Sensor (CKP) is mounted into the right-rear side of the engine block. 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. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. Fig. 17 CKP Sensor Operation And Tonewheel Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 857 On this engine, a tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 858 Crankshaft Position Sensor: Service and Repair Fig. 19 CKP Sensor Location/Removal/Installation REMOVAL The Crankshaft Position (CKP) sensor is located at the right-rear side of the engine cylinder block. It is positioned and bolted into a machined hole in the engine block. 1. Disconnect CKP electrical connector at sensor. 2. Remove CKP mounting bolt. 3. Carefully pry sensor from cylinder block in a rocking action with two small screwdrivers. 4. Remove sensor from vehicle. 5. Check condition of sensor O-ring. INSTALLATION 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into engine block with a slight rocking action. Do not twist sensor into position as damage to O-ring may result CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 28 Nm (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 864 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 865 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 866 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 867 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 868 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 869 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations The lumbar control switch paddle is located in a shallow depression molded into the outer surface of the seat cushion side shield that helps to shroud it from unintentional actuation when entering or leaving the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 873 Seat Belt Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 874 Seat Belt Buckle Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 875 Seat Belt Buckle Switch: Description and Operation LUMBAR CONTROL SWITCH The 8-way power seat option includes an electrically operated lumbar support mechanism. A single two-way momentary power lumbar switch is integral with the power seat switches. The power lumbar switch is secured to the back of the seat cushion side shield with screws, and the switch paddle protrudes through a hole to the outside of the shield. The switch paddle is located in a shallow depression molded into the outer surface of the seat cushion side shield that helps to shroud it from unintentional actuation when entering or leaving the vehicle. The power lumbar switches cannot be adjusted or repaired and, if faulty or damaged, the seat switch assembly must be replaced. When the power lumbar switch paddle is actuated, a battery feed and a ground path are applied through the switch contacts to the power lumbar adjuster motor. The motor operates to move the lumbar adjuster through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the motor to run in the opposite direction. The power lumbar switch should not be held applied in either direction after the adjuster has reached its travel limit. The power lumbar adjuster motor contains a self-resetting circuit breaker to protect it from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. SEAT BELT SWITCH The seat belt switch is a small, normally open, single pole, single throw, plunger actuated, momentary switch. Only one seat belt switch is installed in the vehicle, and it is integral to the driver seat belt retractor assembly. The seat belt switch is connected to the vehicle electrical system through a short pigtail wire to a dedicated take out and connector of the body wire harness. The seat belt switch cannot be adjusted or repaired and, if faulty or damaged, the entire driver seat belt and retractor unit must be replaced. The seat belt switch is designed to control a path to ground for the seat belt switch sense input of the Electro-Mechanical Instrument Cluster (EMIC). The seat belt switch plunger is actuated by the seat belt webbing wound onto the seat belt retractor spool. When the seat belt tip-half webbing is pulled out of the retractor far enough to engage the seat belt buckle-half, the switch plunger is extended and closes the seat belt switch sense circuit to ground; and, when the seat belt tip-half webbing is wound onto the retractor the switch plunger is depressed, opening the ground path. The EMIC monitors the seat belt switch status, then controls the seatbelt indicator and sends electronic chime request messages over the Programmable Communications Interface (PCI) data bus to the Central Timer Module (CTM) based upon that input. The seat belt switch receives ground through its pigtail wire connection to the body wire harness from another take out of the body wire harness. An eyelet terminal connector on that ground take out is secured under a ground screw to the left lower B-pillar. The seat belt switch is connected in series between ground and the seat belt switch sense input of the EMIC. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 876 Seat Belt Buckle Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the seat belt switch from the seat belt switch pigtail wire connector from the driver side front seat belt retractor. Check for continuity between the ground circuit cavity of the body wire harness connector for the seat belt switch and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the open ground circuit to ground (G307) as required. 2. Check for continuity between the two cavities in the seat belt switch pigtail wire connector. There should be no continuity with the seat belt webbing retracted, and continuity with the seat belt webbing pulled out of the retractor far enough to engage the seat belt buckle. If OK, go to Step 3 .If not OK, replace the faulty driver side front seat belt and retractor unit. 3. Remove the instrument cluster from the instrument panel. Check for continuity between the seat belt switch sense circuit cavity of the body wire harness connector for the seat belt switch and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, repair the shorted seat belt switch sense circuit between the seat belt switch and the instrument cluster as required. 4. Check for continuity between the seat belt switch sense circuit cavities of the instrument panel wire harness connector (Connector C2) for the instrument cluster and the body wire harness connector for the seat belt switch. There should be continuity. If OK, proceed to the diagnosis for the instrument cluster. (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). If not OK, repair the open seat belt switch sense circuit between the seat belt switch and the instrument cluster as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 877 Seat Belt Buckle Switch: Service and Repair REMOVAL The power lumbar switch is integral with the other power seat switches. Refer to the appropriate driver or passenger power front seat switch removal and/or installation procedure. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Fig. 1 Battery Temperature Sensor Location The battery temperature sensor is located under vehicle battery and is attached to a mounting hole on battery tray. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 882 Battery Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 883 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and 02 sensor heater tests). Most OBD II monitors are disabled below 20 degrees F. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 884 Battery Temperature Sensor: Testing and Inspection Tests 1 - 2 SYMPTOM CHECKING THE AMBIENT/BATTERY TEMPERATURE SENSOR POSSIBLE CAUSES - Ambient/Battery temperature sensor - Ambient/Battery temperature sensor (Out Of Calibration) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 885 Battery Temperature Sensor: Service and Repair Fig. 1 Battery Temperature Sensor Location REMOVAL The battery temperature sensor is located under vehicle battery (Fig. 1) and is attached to a mounting hole on battery tray. 1. Remove battery. Refer to Battery for procedures. 2. Disconnect sensor pigtail harness from engine wire harness. Sensor pigtail harness is clipped to vehicle near its electrical connector. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION The battery temperature sensor is located under vehicle battery (Fig. 1) and is attached to a mounting hole on battery tray. 1. Feed pigtail harness through hole in top of battery tray and press sensor into top of battery tray. 2. Connect pigtail harness. 3. Install battery. Refer to Battery for procedures. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications Power Steering Pressure Switch: Specifications Power Steering Pressure Switch ............................................................................................................................................... 14-22 Nm (124-195 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 891 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 892 Power Steering Pressure Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 893 Power Steering Pressure Switch: Description and Operation DESCRIPTION A pressure sensing switch is included in the power steering system (mounted on the high pressure line). This switch will be used only on vehicles equipped with a 4.7L V-8 engine and power steering. OPERATION The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high pump load and low engine rpm; such as during parking maneuvers. The PCM will then increase the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load. When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the normally closed switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling. When pump pressure drops to approximately 1379 kPa (200 psi), the switch circuit will re-close and engine idle speed will return to its previous setting. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 894 Power Steering Pressure Switch: Service and Repair REMOVAL The power steering pressure switch is installed in the power steering high-pressure hose. 1. Disconnect electrical connector from power steering pressure switch. 2. Place a small container or shop towel beneath switch to collect any excess fluid. 3. Remove switch. Use back-up wrench on power steering line to prevent line bending. INSTALLATION This switch is used only with 4.7L V-8 engine. 1. Install power steering switch into power steering line. 2. Tighten to 14-22 Nm (124-195 inch lbs.) torque. 3. Connect electrical connector to switch. 4. Check power steering fluid and add as necessary. 5. Start engine and again check power steering fluid. Add fluid if necessary. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Service and Repair Fluid Pressure Sensor/Switch: Service and Repair LINE PRESSURE (LP) SENSOR REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pressure sensor (Fig. 81). 4. Remove the bolt holding the line pressure sensor to the transmission case. 5. Remove the line pressure sensor from the transmission case. INSTALLATION 1. Install the line pressure sensor into the transmission case. 2. Install the bolt to hold the line pressure sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 in. lbs.). 3. Install the wiring connector onto the line pressure sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 903 Overdrive Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 904 Overdrive Switch: Description and Operation DESCRIPTION The overdrive OFF (control) switch is located in the shift lever arm (Fig. 95). The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function. OPERATION At key-on, overdrive operation is allowed. Pressing the switch once causes the overdrive OFF mode to be entered and the overdrive OFF switch lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the overdrive lamp to be turned off. The overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the control switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4 upshift. The control switch indicator light illuminates only when the overdrive switch is turned to the OFF position, or when illuminated by the transmission control module. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 905 Overdrive Switch: Service and Repair REMOVAL 1. Using a plastic trim tool, remove the overdrive off switch retainer from the shift lever (Fig. 96). 2. Pull the switch outwards to release it from the connector in the lever (Fig. 97) INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector out of the lever just enough to grasp it. CAUTION: Be careful not to bend the pins on the overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 906 2. Install the overdrive off switch into the connector (Fig. 98) 3. Push the overdrive off switch and wiring into the shift lever. 4. Install the overdrive off switch retainer onto the shift lever. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Transmission Position Switch/Sensor: Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 913 Transmission Position Switch/Sensor: Description and Operation DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has six switch contacts that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. - Supply ground to the TCM for backup lamp control in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > 42RE (A-500) 4 Speed Transmission Speed Sensor: Specifications Sensor, trans speed 20 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > 42RE (A-500) 4 Speed > Page 918 Transmission Speed Sensor: Specifications Bolt, input speed sensor 105 in.lb Bolt, output speed sensor 105 in.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > 42RE (A-500) 4 Speed > Page 919 Transmission Speed Sensor: Specifications Sensor, trans speed 20 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 920 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor Input Speed Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor > Page 923 Output Speed Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Input Speed Sensor Transmission Speed Sensor: Description and Operation Input Speed Sensor DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Input Speed Sensor > Page 926 Transmission Speed Sensor: Description and Operation Output Speed Sensor OUTPUT SPEED SENSOR DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor Transmission Speed Sensor: Service and Repair Input Speed Sensor REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (Fig. 80). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor from the transmission case. INSTALLATION 1. Install the input speed sensor into the transmission case. 2. Install the bolt to hold the input speed sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the input speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor > Page 929 Transmission Speed Sensor: Service and Repair Output Speed Sensor OUTPUT SPEED SENSOR REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor (Fig. 94). 4. Remove the bolt holding the output speed sensor to the transmission case. 5. Remove the output speed sensor from the transmission case. INSTALLATION 1. Install the output speed sensor into the transmission case. 2. Install the bolt to hold the output speed sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the output speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 933 Transmission Temperature Sensor/Switch: Description and Operation DESCRIPTION The transmission temperature sensor is a thermistor that is integral to the Transmission Range Sensor (TRS). OPERATION The transmission temperature sensor is used by the TCM to sense the temperature of the fluid in the sump. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. Calculated Temperature A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Overdrive Switch, M/T > Component Information > Diagrams Overdrive Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Service Precautions Rear Window Defogger Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Service Precautions > Page 942 Rear Window Defogger Switch: Description and Operation The rear window defogger switch is integral to the heater-A/C control assembly, which includes the rear wiper and washer switches. The rear window switch also contains the rear window defogger logic and timer circuitry, an amber defogger indicator lamp, the rear window defogger relay, and two switch illumination lamps. The indicator and illumination lamps in the switch pod use incandescent bulbs, which can be serviced. The momentary-type rear window defogger switch provides a hard wired ground signal to the rear window defogger logic and timer circuitry, each time it is depressed. The rear window defogger timer and logic circuitry responds by energizing or de-energizing the rear window defogger relay and the amber defogger indicator lamp, which lights to indicate when the defogger system is turned ON. Energizing the rear window defogger relay provides electrical current to the rear window defogger grid. The rear window switch cannot be repaired. If any function of the switch except lighting is faulty or damaged, the entire heater-A/C control assembly must be replaced. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Service Precautions > Page 943 Rear Window Defogger Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Remove the lower bezel from the instrument panel and unplug the rear window switch wire harness connector. 2. Check for continuity between the ground circuit cavity of the rear window switch wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open circuit as required. 3. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the rear window switch pod wire harness connector. If OK, go to Step 4. If not OK, repair the circuit to the Power Distribution Center (PDC) fuse as required. 4. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run) circuit cavity of the rear window switch wire harness connector. If OK, go to Step 5. If not OK, repair the circuit to the junction block fuse as required. 5. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Plug the wire harness connector into the rear window switch. Connect the battery negative cable. Turn the ignition switch to the ON position. Back probe the rear window defogger relay output circuit cavity of the rear window switch pod wire harness connector. Depress and release the rear window defogger switch. There should be battery voltage. Depress and release the rear window defogger switch again. There should be zero volts. If OK, go to Step 6. If not OK, replace the faulty rear window switch pod. 6. Depress and release the rear window defogger switch. The rear window defogger indicator lamp should light. If the indicator lamp does not light, replace the bulb with a known good unit and test again. If the lamp is still inoperative, replace the faulty heater-A/C control assembly. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Service Precautions > Page 944 Rear Window Defogger Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the heater-A/C Control assembly (Refer to HEATING & AIR CONDITIONING/CONTROLS/A/C HEATER CONTROL - REMOVAL). Note: Rear Window Defogger Switch is part of the heater-A/C Control assembly and is not a replaceable component. If damaged or inoperative the entire heater-A/C control assembly must be replaced. INSTALLATION 1. Install the heater-A/C control assembly (Refer to HEATING & AIR CONDITIONING/CONTROLS/A/C HEATER CONTROL INSTALLATION). 2. Install the negative battery cable. Note: The rear window defogger switch is part of the heater-A/C Control assembly, if damaged or inoperative the entire heater-A/C Control assembly must be replaced. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams Power Window Switch: Diagrams Left Rear Door Power Window Switch Passenger Door Power Window Switch Right Rear Door Power Window Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 948 Power Window Switch: Description and Operation The power windows are controlled by two-way switches integral to the power window and lock switch and bezel unit on the trim panel of each front door. A second power window switch in the driver side switch and bezel unit allows the driver to control the passenger windows. The power window switch for the driver side front door window has an Auto label on it. This switch has a second detent position beyond the normal Down position that provides an automatic one-touch window down feature. This feature is controlled by an electronic circuit and a relay that are integral to the Driver Door Module. The power window switches control the battery and ground feeds to the power window motors. All of the passenger door power window switches receive their battery and ground feeds through the circuitry of the Driver Door Module. When the power window lockout switch is in the Lock position, the battery feed for the individual passenger door power window switches is interrupted. A Light-Emitting Diode (LED) in the paddle of each switch is illuminated whenever the ignition switch is in the ON position. However, the LEDs for the passenger power window switches are extinguished whenever the driver selects the Lock position with the power window lockout switch. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 949 Power Window Switch: Testing and Inspection The Light-Emitting Diode (LED) illumination lamps for all of the power window and lock switch and bezel unit switch paddles receive battery current through the power window circuit breaker in the junction block. If all of the LEDs are inoperative in both the power window and lock switch units and the power windows are inoperative, (Refer to POWER WINDOWS - DIAGNOSIS AND TESTING). If the power windows operate, but any or all of the LEDs are inoperative, the power window and lock switch units with the inoperative LED(s) is faulty and must be replaced. 1. Check the circuit breaker in the junction block. If OK, go to Step 2. If not OK, replace the faulty circuit breaker. 2. Turn the ignition switch to the ON position. Check for battery voltage at the circuit breaker in the junction block. If OK, turn the ignition switch to the OFF position and go to Step 3. If not OK, repair the circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Remove the power window switch unit from the door trim panel (passenger doors). The drivers door switch is included with the Driver Door Module (Refer to POWER LOCKS/DOOR MODULE DIAGNOSIS AND TESTING) for service procedures. Unplug the wire harness connector from the switch unit, Passenger Door Switch 4. Test the power window switch continuity. See the Power Window Switch Continuity charts to determine if the continuity is correct in the OFF, Up and Down switch positions. If OK, (Refer to WINDOW MOTOR - DIAGNOSIS AND TESTING). If not OK, replace the faulty switch. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 950 Power Window Switch: Service and Repair REMOVAL The driver side power window switch is included with the Drive Door Module. (Refer to POWER LOCKS/DOOR MODULE - REMOVAL) for the service procedures. 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick, start at the rear of the switch bezel and pry up from door trim panel 3. Disconnect the wire harness connector from switch. 4. Remove switch from bezel. INSTALLATION The driver side power window switch is included with the Drive Door Module. (Refer to POWER LOCKS/DOOR MODULE - INSTALLATION) for the service procedures. 1. Install switch to bezel. 2. Connect wire harness connector to switch. 3. Insert the front of the switch into the door trim panel first, then press into position. 4. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Washer Fluid Level Switch: Locations The washer fluid level switch is a single pole, single throw reed-type switch mounted on the outboard side of the washer reservoir forward of the two washer pump/motors, in the right front corner of the engine compartment. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 955 Washer Fluid Level Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 956 Washer Fluid Level Switch: Description and Operation The washer fluid level switch is a single pole, single throw reed-type switch mounted on the outboard side of the washer reservoir forward of the two washer pump/motors, in the right front corner of the engine compartment. Only the molded plastic switch mounting flange and connector receptacle are visible when the switch is installed in the reservoir. A short nipple formation extends from the inner surface of the switch mounting flange, and a barb on the nipple near the switch mounting flange is press-fit into a rubber grommet seal installed in the mounting hole of the reservoir. A small plastic float pivots on the end of a bracket that extends from the switch nipple formation. Within the float is a small magnet, which actuates the reed switch. The washer fluid level switch cannot be adjusted or repaired. If faulty or damaged, the switch must be replaced. The washer fluid level switch uses a pivoting, oblong float to monitor the level of the washer fluid in the washer reservoir. The float contains a small magnet. When the float pivots, the changing proximity of its magnetic field will cause the contacts of the small, stationary reed switch to open or close. When the fluid level in the washer reservoir is at or above the float level, the float moves to a vertical position and the switch contacts open. When the fluid level in the washer reservoir falls below the pivoting float, the float moves to a horizontal position and the switch contacts close. The switch contacts are connected in series between ground and the washer fluid switch sense input of the instrument cluster. The switch is connected to the vehicle electrical system through a dedicated take out and connector of the headlamp and dash wire harness. The switch receives ground through another take out of the headlamp and dash wire harness with a single eyelet terminal connector that is secured under a nut to a ground stud located on the right front fender inner shield in the engine compartment. The washer fluid level switch can be diagnosed using conventional diagnostic tools and methods. (Refer to WASHER FLUID INDICATOR - DIAGNOSIS AND TESTING). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 957 Washer Fluid Level Switch: Service and Repair REMOVAL The washer fluid level switch can be removed from the washer reservoir without removing the reservoir from the vehicle. 1. Disconnect and isolate the battery negative cable. 2. Disconnect the washer hose from the barbed outlet nipple of the washer pump/motor unit and allow the washer fluid to drain into a clean container for reuse. Fig. 11 Washer Fluid Level Switch 3. Disconnect the headlamp and dash wire harness connector for the washer fluid level switch from the switch connector receptacle. NOTE: The pivoting float of the washer fluid level switch must be in a horizontal position within the reservoir in order to be removed. With the reservoir empty and in an upright position, the pivoting float will orient itself to the horizontal position when the switch connector receptacle is pointed straight downwards. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed nipple of the washer fluid level switch out of the rubber grommet seal on the outboard side of the reservoir. Care must be taken not to damage the reservoir. 5. Remove the washer fluid level switch and float from the washer reservoir. 6. Remove the rubber grommet seal from the washer fluid level switch mounting hole in the washer reservoir and discard. INSTALLATION 1. Install a new rubber grommet seal into the washer fluid level switch mounting hole in the outboard side of the washer reservoir. Always use a new rubber grommet seal on the reservoir. 2. Position the float of the washer fluid level switch through the rubber grommet seal in the washer reservoir. The connector receptacle of the washer fluid level switch should be pointed downward. 3. Press firmly and evenly on the washer fluid level switch using hand pressure until the barbed nipple is fully seated in the rubber grommet seal in the washer reservoir mounting hole. 4. Reconnect the headlamp and dash wire harness connector for the washer fluid level switch to the switch connector receptacle. 5. Reconnect the washer hose to the barbed outlet nipple of the washer pump/motor unit. 6. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications Alignment: Specifications NOTE: All alignment specifications are in degrees. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 962 Alignment: Description and Operation DESCRIPTION Wheel alignment involves the correct positioning of the wheels in relation to the vehicle. The positioning is accomplished through suspension and steering linkage adjustments. An alignment is considered essential for efficient steering, good directional stability and to minimize tire wear. The most important measurements of an alignment are caster, camber and toe. CAUTION: Never attempt to modify suspension or steering components by heating or bending. NOTE: Periodic lubrication of the front suspension/steering system components may be required. Rubber bushings must never be lubricated. OPERATION - CASTER is the forward or rearward tilt of the steering knuckle from vertical. Tilting the top of the knuckle forward provides negative caster. Tilting the top of the knuckle rearward provides positive caster. Positive caster promotes directional stability. This angle enables the front wheels to return to a straight ahead position after turns. - CAMBER is the inward or outward tilt of the wheel relative to the center of the vehicle. Tilting the top of the wheel inward provides negative camber. Tilting the top of the wheel outward provides positive camber. Incorrect camber will cause wear on the inside or outside edge of the tire. - TOE is the difference between the leading inside edges and trailing inside edges of the front tires. wheel position out of specification cause's unstable steering, uneven tire wear and steering wheel off center. The wheel toe position is the final front wheel alignment adjustment. - THRUST ANGLE is the angle of the rear axle relative to the centerline of the vehicle. Incorrect thrust angle can cause off-center steering and excessive tire wear. This angle is not adjustable, damaged component(s) must be replaced to correct the thrust angle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Pre-Alignment Inspection Alignment: Service and Repair Pre-Alignment Inspection DIAGNOSIS AND TESTING - PRE-ALIGNMENT INSPECTION Before starting wheel alignment, the following inspection and necessary corrections must be completed. 1. Inspect tires for size, air pressure and tread wear. 2. Inspect front wheel bearings for wear. 3. Inspect front wheels for excessive radial or lateral runout and balance. 4. Inspect ball studs, linkage pivot points and steering gear for looseness, roughness or binding. 5. Inspect suspension components for wear and noise. 6. On 4x4 vehicles check suspension height. 7. Road test the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 965 Alignment: Service and Repair Wheel Alignment STANDARD PROCEDURE - HEIGHT MEASUREMENT The vehicle suspension height should be measured and adjusted if necessary before performing wheel alignment procedure. Also when front suspension components have been replaced. This measure must be performed with the vehicle supporting it's own weight and taken on both sides of the vehicle. 1. Jounce the front of the vehicle. 2. Measure and record the distance between the ground and the center of the lower suspension arm rear mounting bolt head. 3. Measure and record the distance between the ground and the center of the front wheel. 4. Subtract the first measurement from the second measurement. The difference between the two measurement should be 73 mm (2.9 inches) + 3 mm (0.12 inches). STANDARD PROCEDURE- HEIGHT ADJUSTMENT The vehicle suspension height should be measured and adjusted if necessary before performing wheel alignment procedure. Also when front suspension components have been replaced. This measure must be performed with the vehicle supporting it's own weight and taken on both sides of the vehicle. To adjust the vehicle height turn the torsion bar adjustment bolt CLOCKWISE to raise the vehicle and COUNTER CLOCKWISE to lower the vehicle. CAUTION: ALWAYS raise the vehicle to the correct suspension height, NEVER lower the vehicle to obtain the correct suspension height. If the vehicle suspension height is too high, lower the vehicle below the height specification. Then raise the vehicle to the correct suspension height specification. This will insure the vehicle maintains the proper suspension height. NOTE: If a height adjustment has been made, perform height measurement again on both sides of the vehicle. STANDARD PROCEDURE - CAMBER AND CASTER ADJUSTMENT Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 966 Camber and caster angle adjustments involve changing the position of the upper suspension arm pivot bar. NOTE: On 4x2 vehicles use Alignment Tool 8393 for alignment. The tool attaches to the pivot bar on the upper control arm. STANDARD PROCEDURE- CASTER Moving the rear position of the pivot bar in or out, will change the caster angle significantly and camber angle only slightly. To maintain the camber angle while adjusting caster, move the rear of the pivot bar in or out. Then move the front of the pivot bar slightly in the opposite direction. To increase positive caster angle, move the rear position of the pivot bar inward (toward the engine). Move the front of pivot bar outward (away from the engine) slightly until the original camber angle is obtained. STANDARD PROCEDURE - CAMBER Move the front of the pivot bar in or out. This will change the camber angle significantly and caster angle slightly. After adjustment is made tighten the pivot bar nuts to proper torque specification. STANDARD PROCEDURE - TOE ADJUSTMENT The wheel toe position adjustment is the final adjustment. 1. Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheel with the front wheels in the straight-ahead position. 2. Loosen the tie rod jam nuts. NOTE: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straight-ahead. 3. Adjust the wheel toe position by turning the tie rod as necessary. 4. Tighten the tie rod jam nut to 75 Nm (55 ft. lbs.). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 967 5. Verify the specifications 6. Turn oh engine. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL Housing removal is not necessary for element (filter) replacement. 1. Pry up spring clips from housing cover (spring clips retain cover to housing). 2. Release housing cover from locating tabs on housing (Fig. 11) and remove cover. 3. Remove air cleaner element (filter) from housing. 4. Clean inside of housing before replacing element. INSTALLATION 1. Install element into housing. 2. Position housing cover into housing locating tabs. 3. Pry up spring clips and lock cover to housing. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions 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 °C (1000 °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. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 984 Fuel Pressure Release: Service and Repair Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator Clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications ENGINE FIRING ORDER - 4.7L V-8 4.7L ENGINE DESCRIPTION Fig. 1 The 4.7 liter (287 CID) eight-cylinder engine is an 90° single overhead camshaft engine. The cast iron cylinder block is made up of two different components; the first component is the cylinder bore and upper block, the second component is the bedplate that comprises the lower portion of the cylinder block and houses the lower half of the crankshaft main bearings. The cylinders are numbered from front to rear with the left bank being numbered 1,3,5 and 7, and the right bank being numbered 2,4,6 and 8. The firing order is 1-8-4-3-6-5-7-2. The engine serial number is located at the Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 989 right front side of the engine block (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 990 Firing Order - 4.7L V-8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Firing Order - 4.7L V-8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Specifications Distributor: Specifications Distributor Holddown Bolt .................................................................................................................... .................................................. 23 Nm (17 Ft. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Specifications > Page 998 Distributor: Service Precautions WARNING: WHEN PERFORMING THE FOLLOWING TEST, THE ENGINE WILL BE RUNNING. BE CAREFUL NOT TO STAND IN LINE WITH THE FAN BLADES OR FAN BELT. DO NOT WEAR LOOSE CLOTHING. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Plug Gap .............................................................................................................................................. .................................................... 1.01 mm (0.040 in.) Tightening Torque ............................................................................................................................... ...................................................... 27 Nm (20 ft. lbs.) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1002 Spark Plug: Locations The spark plug is located under each ignition coil. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1003 Spark Plug: Application and ID Plug Type ............................................................................................................................................ ............................................................... RC12MCC4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1004 Spark Plug: Description and Operation This engine are equipped with "fired in suppressor seal" type spark plugs using a copper core ground electrode. Because of the use of an aluminum cylinder head on this engine, spark plug torque is very critical. To prevent possible pre-ignition and/or mechanical engine damage, the correct type/heat range/number spark plug must be used. 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 intervals recommended in Lubrication and Maintenance. Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or oil fouled. Also refer to Spark Plug Conditions. 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1005 Spark Plug: Testing and Inspection SPARK PLUG CONDITIONS Fig. 20 Normal Operation And Cold (Carbon) Fouling Normal Operating 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. On this engine gap growth will not average more than approximately 0.0015 in per 3200 km (2000 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 may be affected by MMT deposits. Cold Fouling/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 cleaner element or repeated short operating times (short trips). 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1006 Fig. 21 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. Fig. 22 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1007 Fig. 23 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 fuses. 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. Fig. 24 Chipped Electrode 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1008 Fig. 25 Preignition Damage 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.) Fig. 26 Spark Plug 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 2000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions can also cause spark plug overheating. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1009 Spark Plug: Service and Repair REMOVAL 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. In this engine: Each individual spark plug is located under each ignition coil. Each individual ignition coil must be removed to gain access to each spark plug. Refer to Ignition Coil Removal/Installation. 1. In this engine: Prior to removing spark plug, spray compressed air around base of ignition coil at cylinder head. This will help prevent foreign material from entering combustion chamber. 2. Remove spark plug from cylinder head using a quality socket with a rubber or foam insert. If equipped with this engine, also check condition of coil O-ring and replace as necessary. 3. Inspect spark plug condition. Refer to Spark Plug Conditions. CLEANING The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean spark plugs. Metallic deposits will remain on spark plug insulator and will cause plug misfire. INSTALLATION CAUTION: This engine is equipped with copper core ground electrode spark plugs. They must be replaced with the same type/number spark plug as the original. If another spark plug is substituted, pre-ignition will result. 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. 1. Start the spark plug into the cylinder head by hand to avoid cross threading. 2. In this engine: Tighten spark plugs to 27 Nm (20 ft. lbs.) torque. 3. In this engine: Before installing coil(s), check condition of coil O-ring and replace as necessary. To aid in coil installation, apply silicone to coil O-ring. 4. In this engine: Install ignition coil(s). Refer to Ignition Coil Removal/Installation. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications CYLINDER COMPRESSION PRESSURE RANGE: Compression Pressure ........................................................................................................................ ............................................................... 140 - 180 psi Maximum Allowable Variance Between Cylinders ....................................................................................................................................................... 25 % Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1013 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Secure the throttle in the wide-open position. 4. Disable the fuel system. 5. Remove the ASD relay. 6. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. 7. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders. 8. Refer to SPECIFICATIONS for the correct engine compression pressures. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Timing Component Alignment Marks > Component Information > Locations Timing Component Alignment Marks: Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Timing Component Alignment Marks > Component Information > Locations > Page 1020 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection Drive Belt: Testing and Inspection VISUAL DIAGNOSIS When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface of the belt from rib to rib (Fig. 9), are considered normal. These are not a reason to replace the belt. However, cracks running along a rib (not across) are not normal. Any belt with cracks running along a rib must be replaced (Fig. 9). Also replace the belt if it has excessive wear, frayed cords or severe glazing. Refer to ACCESSORY DRIVE BELT DIAGNOSIS CHART for further belt diagnosis. NOISE DIAGNOSIS Noises generated by the accessory drive belt are most noticeable at idle. Before replacing a belt to resolve a noise condition, inspect all of the accessory drive pulleys for alignment, glazing, or excessive end play. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 1024 ACCESSORY DRIVE BELT DIAGNOSIS CHART Part 1 of 2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 1025 ACCESSORY DRIVE BELT DIAGNOSIS CHART Part 2 of 2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 1026 Drive Belt: Service and Repair REMOVAL CAUTION: DO NOT LET TENSIONER ARM SNAP BACK TO THE FREE ARM POSITION, SEVER DAMAGE MAY OCCUR TO THE TENSIONER. Belt tension is not adjustable. Belt adjustment is maintained by an automatic (spring load) belt tensioner. 1. Disconnect negative battery cable from battery. 2. Rotate belt tensioner until it contacts it's stop. Remove belt, then slowly rotate the tensioner into the free arm position. (Fig. 10). INSTALLATION Belt tension is not adjustable. Belt adjustment is maintained by an automatic (spring load) belt tensioner. 1. Check condition of all pulleys. CAUTION: When installing the serpentine accessory drive belt, the belt MUST be routed correctly. If not, the engine may overheat due to the water pump rotating in the wrong direction (Fig. 10). 2. Install new belt (Fig. 10). Route the belt around all pulleys except the idler pulley. Rotate the tensioner arm until it contacts it's stop position. Route the belt around the idler and slowly let the tensioner rotate into the belt. Make sure the belt is seated onto all pulleys. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 1027 3. With the drive belt installed, inspect the belt wear indicator (Fig. 11). On 4.7L Engines only, the gap between the tang and the housing stop (measurement A) must not exceed 24 mm. (0.94 inches). If the measurement exceeds this specification replace the serpentine accessory drive belt. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL Housing removal is not necessary for element (filter) replacement. 1. Pry up spring clips from housing cover (spring clips retain cover to housing). 2. Release housing cover from locating tabs on housing (Fig. 11) and remove cover. 3. Remove air cleaner element (filter) from housing. 4. Clean inside of housing before replacing element. INSTALLATION 1. Install element into housing. 2. Position housing cover into housing locating tabs. 3. Pry up spring clips and lock cover to housing. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Application and ID Cabin Air Filter: Application and ID This vehicle is not equipped with a cabin air filter. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; Fluid Filter - A/T: Customer Interest A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; NUMBER: 21-015-05 GROUP: Transmission DATE: September 01, 2005 SUBJECT: 45RFE / 545RFE Trans - Delayed Engagement Due To Cooler Return Filter Replacement OVERVIEW: This bulletin involves a transmission delayed shift condition that may occur following the replacement of the internal cooler return filter. MODELS: 2000 - 2004 (AN) Dakota 2000 - 2003 (DN) Durango 2003 - 2006 (DR) Ram Truck 2004 - 2006 (HB) Durango 2002 - 2006 (KJ) Liberty 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - 2006 (WK/WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with a 45RFE or a 545RFE automatic transmission (sales code DG4 or DGQ respectively). DISCUSSION: The customer may experience an initial delayed shift engagement following an extended off (not running) period of time, generally after being parked overnight. The initial shift engagement may feel like a delay or slip when a transmission gear (reverse or drive) is first selected after engine start. The customer may not have experienced the delayed shift engagement until after the transmission has been serviced, where the cooler return filter was replaced during the service and/or repair. The condition is not detrimental to the transmission but may cause concern with the customer. The above condition may be caused by a suspect cooler return filter a part number of 04799662AB. This "AB" suffix / level filter may allow transmission fluid to drain back out of the torque converter. The drain back condition may occur over a period time when the engine (and transmission) are not running. With less fluid in the torque converter a delay in gear engagement may occur at engine start up while the torque converter fills to its proper fluid level. All 04799662AB cooler return filters with the "AB" suffix are suspect. The above condition may be corrected by replacing a suspect "AB" filter with a new cooler return filter whose part number is 04799662 (with no suffix or with a suffix that is other than the "AB" level). NOTE: The cooler return filter, p/n 04799662, will not be available until September 09, 2005. The filter part number is stenciled on the side of the filter case. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; > Page 1044 NOTE: A replacement 04799662 cooler return filter may come packaged with a separate threaded adapter stud. The threaded adapter stud is used to attach the cooler return filter to the transmission. Inspect the stud and note end without threads. Install the stud end without the threads into the cooler return filter and tighten the stud-to-filter connection to 18.6 Nm (165 in. lbs.). Once the threaded adapter stud has been installed to the cooler return filter, install the assembled cooler return filter to the transmission and tighten the filter to 14.1 Nm (125 in. lbs.) POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; Fluid Filter - A/T: All Technical Service Bulletins A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; NUMBER: 21-015-05 GROUP: Transmission DATE: September 01, 2005 SUBJECT: 45RFE / 545RFE Trans - Delayed Engagement Due To Cooler Return Filter Replacement OVERVIEW: This bulletin involves a transmission delayed shift condition that may occur following the replacement of the internal cooler return filter. MODELS: 2000 - 2004 (AN) Dakota 2000 - 2003 (DN) Durango 2003 - 2006 (DR) Ram Truck 2004 - 2006 (HB) Durango 2002 - 2006 (KJ) Liberty 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - 2006 (WK/WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with a 45RFE or a 545RFE automatic transmission (sales code DG4 or DGQ respectively). DISCUSSION: The customer may experience an initial delayed shift engagement following an extended off (not running) period of time, generally after being parked overnight. The initial shift engagement may feel like a delay or slip when a transmission gear (reverse or drive) is first selected after engine start. The customer may not have experienced the delayed shift engagement until after the transmission has been serviced, where the cooler return filter was replaced during the service and/or repair. The condition is not detrimental to the transmission but may cause concern with the customer. The above condition may be caused by a suspect cooler return filter a part number of 04799662AB. This "AB" suffix / level filter may allow transmission fluid to drain back out of the torque converter. The drain back condition may occur over a period time when the engine (and transmission) are not running. With less fluid in the torque converter a delay in gear engagement may occur at engine start up while the torque converter fills to its proper fluid level. All 04799662AB cooler return filters with the "AB" suffix are suspect. The above condition may be corrected by replacing a suspect "AB" filter with a new cooler return filter whose part number is 04799662 (with no suffix or with a suffix that is other than the "AB" level). NOTE: The cooler return filter, p/n 04799662, will not be available until September 09, 2005. The filter part number is stenciled on the side of the filter case. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; > Page 1050 NOTE: A replacement 04799662 cooler return filter may come packaged with a separate threaded adapter stud. The threaded adapter stud is used to attach the cooler return filter to the transmission. Inspect the stud and note end without threads. Install the stud end without the threads into the cooler return filter and tighten the stud-to-filter connection to 18.6 Nm (165 in. lbs.). Once the threaded adapter stud has been installed to the cooler return filter, install the assembled cooler return filter to the transmission and tighten the filter to 14.1 Nm (125 in. lbs.) POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Page 1051 Fluid Filter - A/T: Specifications Screws, fluid filter 35 in.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Level Check Fluid Filter - A/T: Service and Repair Fluid Level Check FLUID LEVEL CHECK Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmission has too much fluid, the geartrain churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. Along with fluid level, it is important to check the condition of the fluid. When the fluid smells burned, and is contaminated with metal or friction material particles, a complete transmission recondition is needed. Be sure to examine the fluid on the dipstick closely. If there is any doubt about its condition, drain out a sample for a double check. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. The transmission has a dipstick to check oil level. It is located on the right side of the engine. Be sure to wipe all dirt from dipstick handle before removing. The torque converter fills in both the P (PARK) and N (NEUTRAL) positions. Place the selector lever in P (PARK) to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature (approximately 82°C. or 180°F.), the fluid level is correct if it is in the HOT region (cross-hatched area) on the oil level indicator. The fluid level will be approximately at the upper COLD hole of the dipstick at 70°F fluid temperature. NOTE: Engine and Transmission should be at normal operating temperature before performing this procedure. 1. Start engine and apply parking brake. 2. Shift the transmission into DRIVE for approximately 2 seconds. 3. Shift the transmission into REVERSE for approximately 2 seconds. 4. Shift the transmission into PARK. 5. Hook up DRB@ scan tool and select transmission. 6. Select sensors. 7. Read the transmission temperature value. 8. Compare the fluid temperature value with the chart. 9. Adjust transmission fluid level shown on the dipstick according to the chart. NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the transmission before rechecking the fluid level. 10. Check transmission for leaks. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Level Check > Page 1054 Fluid Filter - A/T: Service and Repair Fluid and Filter Service STANDARD PROCEDURE - FLUID AND FILTER REPLACEMENT REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission. 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolts holding pan to transmission. 7. While holding pan level, lower pan away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove screw holding filter to valve body (Fig. 54). 10. Separate filter from valve body and oil pump and pour fluid in filter into drain pan. 11. Remove and discard the oil filter seal from the bottom of the oil pump. 12. If replacing the cooler return filter, use Oil Filter Wrench 8321 to remove the filter from the transmission. 13. Dispose of used trans fluid and filter(s) properly. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Level Check > Page 1055 Transmission Fluid Temperature Chart INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION 1. Install a new oil filter seal into the bottom of the oil pump. NOTE: Do not attempt to install the seal onto the oil filter first and then into the oil pump. An unsatisfactory seal between the oil pump and filter will result, allowing air to be drawn into the pump. 2. Place replacement filter in position on valve body and into the oil pump. 3. Install screw to hold filter to valve body (Fig. 54). Tighten screw to 4.5 Nm (40 inch lbs.) torque. 4. Install new cooler return filter onto the transmission, if necessary. Torque the filter to 14.12 Nm (125 inch lbs.). 5. Place bead of Mopar(R) RTV sealant onto the transmission case sealing surface. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 11.8 Nm (105 inch lbs.) torque. 8. Lower vehicle and fill transmission with Mopar(R) ATF +4, type 9602 fluid. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Level Check > Page 1056 Fluid Filter - A/T: Service and Repair Transmission Fill TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar(R) ATF +4 to transmission: a. If only fluid and filter were changed, add 10 pints (5 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled, torque converter was replaced or drained, and cooler was flushed, add 24 pints (12 quarts) of ATF +4 to transmission. 3. Check the transmission fluid and adjust as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions 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 °C (1000 °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. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1061 Fuel Pressure Release: Service and Repair Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator Clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Locations Fuel Pump Pickup Filter: Locations The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module. The fuel pump module is located inside of fuel tank. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Locations > Page 1065 Fuel Pump Pickup Filter: Service and Repair Fig. 28 Fuel Pump Inlet Filter REMOVAL The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module (Fig. 28). The fuel pump module is located inside of fuel tank. 1. Remove fuel tank. 2. Remove fuel pump module. 3. Remove filter by carefully prying 2 lock tabs at bottom of module with 2 screwdrivers. Filter is snapped to module. 4. Clean bottom of pump module. INSTALLATION The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module (Fig. 28). The fuel pump module is located inside of fuel tank. 1. Snap new filter to bottom of module. Be sure O-ring is in correct position. 2. Install fuel pump module. 3. Install fuel tank. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Locations > Page 1069 Oil Filter: Service and Repair REMOVAL All engines are equipped with a high quality full flow, disposable type oil filter. Daimler Chrysler Corporation recommends a Mopar or equivalent oil filter be used. 1. Position a drain pan under the oil filter. 2. Using a suitable oil filter wrench loosen filter. 3. Rotate the oil filter counterclockwise (Fig. 100) to remove it from the cylinder block oil filter boss. 4. When filter separates from cylinder block oil filter boss, tip gasket end upward to minimize oil spill. Remove filter from vehicle. NOTE: Make sure filter gasket was removed with filter. 5. With a wiping cloth, clean the gasket sealing surface of oil and grime. INSTALLATION 1. Lightly lubricate oil filter gasket with engine oil. 2. Thread filter onto adapter nipple. When gasket makes contact with sealing surface, (Fig. 101) hand tighten filter one full turn, do not over tighten. 3. Add oil, verify crankcase oil level and start engine. Inspect for oil leaks. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications Hose/Line HVAC: Specifications Refrigerant Lines at Compressor ............................................................................................................................. 23 N.m (17 Ft. Lbs) (200 ± 30 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications > Page 1074 Hose/Line HVAC: Service Precautions Kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire system. High pressures are produced in the system when it is operating. Extreme care must be exercised to make sure that all refrigerant system connections are pressure tight. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. Sharp bends will reduce the flow of refrigerant. The flexible hose lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. It is a good practice to inspect all flexible refrigerant system hose lines at least once a year to make sure they are in good condition and properly routed. There are two types of refrigerant fittings: - All fittings with O-rings need to be coated with refrigerant oil before installation. Use only O-rings that are the correct size and approved for use with R-134a refrigerant. Failure to do so may result in a leak. - Unified plumbing connections with gaskets cannot be serviced with O-rings. The gaskets are not reusable and new gaskets do not require lubrication before installing. Using the proper tools when making a refrigerant plumbing connection is very important. Improper tools or improper use of the tools can damage the refrigerant fittings. The refrigerant must be recovered completely from the system before opening any fitting or connection. Open the fittings with caution, even after the refrigerant has been recovered. If any pressure is noticed as a fitting is loosened, tighten the fitting and recover the refrigerant from the system again. Do not discharge refrigerant into the atmosphere. Use an R-134a refrigerant recovery/recycling device that meets SAE Standard J2210. The refrigerant system will remain chemically stable as long as pure, moisture-free R-134a refrigerant and refrigerant oil is used. Dirt, moisture, or air can upset this chemical stability. Operational troubles or serious damage can occur if foreign material is present in the refrigerant system. When it is necessary to open the refrigerant system, have everything needed to service the system ready. The refrigerant system should not be left open to the atmosphere any longer than necessary. Cap or plug all lines and fittings as soon as they are opened to prevent the entrance of dirt and moisture. All lines and components in parts stock should be capped or sealed until they are to be installed. All tools, including the refrigerant recycling equipment, the manifold gauge set, and test hoses should be kept clean and dry. All tools and equipment must be designed for R-134a refrigerant. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications > Page 1075 Hose/Line HVAC: Description and Operation REFRIGERANT LINES The refrigerant lines and hoses are used to carry the refrigerant between the various air conditioning system components. A barrier hose design with a nylon tube, which is sandwiched between rubber layers, is used for the R-134a air conditioning system on this vehicle. This nylon tube helps to further contain the R-134a refrigerant, which has a smaller molecular structure than R-12 refrigerant. The ends of the refrigerant hoses are made from lightweight aluminum or steel, and commonly use braze-less fittings. Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. The refrigerant lines and hoses are coupled with other components of the HVAC system with peanut-block style fittings. A stat-O seal type flat steel gasket with a captured compressible O-ring, is used to mate plumbing lines with A/C components to ensure the integrity of the refrigerant system. The refrigerant lines and hoses cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant Recovery, See: Fluids/Refrigerant/Service and Repair/Refrigerant - Recovery 3. Disconnect the refrigerant line at the condenser and the suction line jumper. 4. Remove the screw that secures the refrigerant line manifold to the compressor. Install plugs in, or tape over all of the opened refrigerant line fittings 5. Remove the discharge line assembly from the vehicle. INSTALLATION 1. Install the discharge line assembly to the vehicle. Remove all plugs or tape installed over line connections. 2. Install the screw that secures the refrigerant line manifold to the compressor. Tighten the screw to 22 Nm (200 ± 30 in. lbs.). 3. Connect the refrigerant line at the condenser and the suction line jumper. Tighten to 22 Nm (300 ± 30 in. lbs.) 4. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Evacuate, See: Fluids/Refrigerant/Service and Repair/Refrigerant - Evacuate 5. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Charge, See: Fluids/Refrigerant/Service and Repair/Refrigerant - Charge 7. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1078 Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Replacement REMOVAL Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant Recovery, See: Fluids/Refrigerant/Service and Repair/Refrigerant - Recovery 3. Remove the screw that secures the front liquid line block fitting to the inlet of the filter-drier, and disengage the fitting from the filter-drier. Install plugs in, or tape over all of the opened refrigerant line fittings. 4. Disconnect the front liquid line refrigerant line coupler at the condenser outlet. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the front liquid line from the engine compartment. 6. Disconnect the wiring connector from the Pressure Transducer on the rear liquid line. 7. Remove the screw that secures the rear liquid line to the outlet of the filter-drier and disengage the fitting from the filter-drier. Install plugs or tape over the opened refrigerant line fittings. 8. Remove the screw from the rear liquid line fitting at the expansion valve. Plug or tape over the opened refrigerant line fittings. 9. Remove the rear liquid line from the vehicle. INSTALLATION Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. 1. Remove the tape or plugs from the refrigerant line fittings on the front liquid line and the condenser outlet. Connect the front liquid line to the condenser outlet. 2. Remove the tape or plugs from the front liquid line block fitting and the filter-drier inlet. Install the front liquid line block fitting to the filter-drier inlet and secure the connection with a screw. Tighten the mounting screw to 13.5 Nm (120 in. lbs.). 3. Install the rear liquid line into the vehicle. 4. Remove any plugs or tape installed over the connections. 5. Install the rear liquid line to the expansion valve. 6. Install the rear liquid line to the filter-drier and secure the screw. Tighten the screw to 13.5 Nm (120 in. lbs.). 7. Connect the wiring connector to the Pressure Transducer on the rear liquid line. 8. Connect the battery negative cable. 9. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Evacuate, See: Fluids/Refrigerant/Service and Repair/Refrigerant - Evacuate 10. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Charge, See: Fluids/Refrigerant/Service and Repair/Refrigerant - Charge Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1079 Hose/Line HVAC: Service and Repair A/C Suction Hose/Line Replacement REMOVAL Suction line Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant Recovery, See: Fluids/Refrigerant/Service and Repair/Refrigerant - Recovery 3. Disconnect the refrigerant line block fitting at the condenser and the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings. 4. Remove the screw that secures the refrigerant line manifold to the compressor. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the suction and discharge line assembly from the vehicle. Suction Line Jumper Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant. system connections is pressure-tight and leak free. 1. Disconnect and isolate the battery negative cable. 2. Remove the low pressure cut-off switch from the fitting on the suction line jumper. 3. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant Recovery, See: Fluids/Refrigerant/Service and Repair/Refrigerant - Recovery 4. Disconnect the refrigerant line coupler between the suction line and the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the liquid line from the engine compartment. 6. Slide the plastic retainer that secures the suction line jumper out of the saddle formation at the top of the rear liquid line block fitting. Secure block, preferably in a vise. Tap the plastic retainer out with a hammer and flat-bladed screwdriver. 7. Remove the suction line jumper from the rear liquid line block fitting. INSTALLATION Suction line 1. Remove the tape or plugs from all of the refrigerant line fittings. Install the refrigerant line couplers to the suction line jumper. 2. Install the discharge line to the condenser. Tighten the screws to 22 Nm ( 200 ± 30 in. lbs.) 3. Install the refrigerant line manifold to the compressor. Tighten the mounting screw to 22 Nm (200 ± 30 in. lbs.). 4. Connect the battery negative cable. 5. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant, Refrigerant Evacuate, See: Fluids/Refrigerant/Service and Repair/Refrigerant - Evacuate 6. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Charge, See: Fluids/Refrigerant/Service and Repair/Refrigerant - Charge Suction Line Jumper Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. 1. Using a new O-ring, install the suction line jumper into the saddle formation at the top of the rear liquid line block fitting. 2. Slide the plastic retainer that secures the suction line jumper into the rear liquid line block fitting. 3. Install the rear liquid line into the engine compartment. 4. Remove the tape or plugs from the refrigerant line fittings on the suction line and the suction line jumper. Install the suction line to the suction line jumper. 5. Install the low pressure cut-off switch to the fitting on the suction line jumper. 6. Connect the battery negative cable. 7. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant, Refrigerant Evacuate, See: Fluids/Refrigerant/Service and Repair/Refrigerant - Evacuate Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1080 8. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Charge, See: Fluids/Refrigerant/Service and Repair/Refrigerant - Charge Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1081 Hose/Line HVAC: Service and Repair Rear Underbody A/C Lines Replacement REMOVAL Complete Rear A/C Line 1. Reclaim the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant Recovery, See: Fluids/Refrigerant/Service and Repair/Refrigerant - Recovery 2. Remove air box. 3. Lift vehicle on hoist. 4. Remove passenger side tires. 5. Remove front and rear inner fenders. 6. Disconnect the front underhood a/c line. 7. Disconnect the underbody a/c line assembly at the rear HVAC unit. 8. Remove all body mount bolts on the passenger side and loosen the body mount bolts on the drivers side. 9. Place a jack stand at the front and rear of the vehicle on the passenger side so that the stands will support the body. 10. Detach all underbody a/c assembly brackets from the body that are accessible. 11. Lower the hoist until the body, that is being supported by the stands, is approximately 3-4 inches above the frame. This will allow access to the underbody assembly. 12. Remove all remaining a/c line brackets that were not accessible before the body lift. 13. Remove the complete a/c line assembly from the vehicle. 5/8" Front A/C Tube Repair 1. Discharge and recover refrigerant from a/c system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant Recovery, See: Fluids/Refrigerant/Service and Repair/Refrigerant - Recovery 2. Remove air box. 3. Lift vehicle on hoist. 4. Remove passenger side front tire. 5. Remove passenger side front inner fender well. 6. Disconnect suction line spring lock from suction jumper. 7. Remove and under side brackets as necessary. 8. Mark cut location on the tube on the vehicle. 9. Cut tube on truck. 10. Size replacement tube, same as tube removed from truck. 11. Scuff end of both tubes using pad provided with special tool kit. 12. Select proper Lokring for (5/8") tube. 13. Put a drop of sealer from kit on the end of each tube, install Lokring and rotate to spread sealer evenly. 14. Select the proper jaws for the installation tool (5/8") from the special tool kit. 15. Put installation tool over the Lokring with tubes installed. 16. Compress Lokring using a wrench to draw the screw tight on the installation tool. Tighten the tool until the Lokring is bottomed out. 17. Back off the screw and remove the installation tool. 18. Reconnect the suction line spring lock. 19. Reinstall the passenger side front inner fender well. 20. Install the passenger side tire. 21. Lower the vehicle on the hoist. 22. Reinstall the air box. 23. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Evacuate, See: Fluids/Refrigerant/Service and Repair/Refrigerant - Evacuate 24. Recharge the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Charge, See: Fluids/Refrigerant/Service and Repair/Refrigerant - Charge 3/8" Front A/C Tube Repair 1. Discharge and reclaim the a/c refrigerant. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Recovery, See: Fluids/Refrigerant/Service and Repair/Refrigerant - Recovery 2. Remove the air box. 3. Lift vehicle on an approved hoist. 4. Remove the passenger front tire. 5. Remove the passenger side front inner fender well. 6. Disconnect the liquid line spring lock from the suction jumper. 7. Remove under brackets as necessary. 8. Mark cut location on tube on vehicle. 9. Cut tube on vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1082 10. Size replacement tube, same as tube removed from truck. 11. Scuff end of both tubes using pad provided in special tool kit. 12. Select proper Lokring for (3/8") tube. 13. Put a drop of sealer from kit on the end of each tube, install Lokring and rotate to spread sealer evenly. 14. Select the proper jaws for the installation tool (3/8") from the kit. 15. Put installation tool over the Lokring with tubes installed. 16. Compress Lokring using a wrench to draw the screw tight on the installation tool. Tighten the tool until the Lokring is bottomed out. 17. Back off the screw and remove the installation tool. 18. Reconnect the liquid line spring lock. 19. Reinstall the passenger side inner wheel well. 20. Reinstall the passenger side wheel. 21. Lower the vehicle on the hoist. 22. Reinstall the air box. 23. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Evacuate, See: Fluids/Refrigerant/Service and Repair/Refrigerant - Evacuate 24. Recharge the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Charge, See: Fluids/Refrigerant/Service and Repair/Refrigerant - Charge 5/8" Rear A/C Tube Repair 1. Recover the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Refrigerant - Recovery, See: Fluids/Refrigerant/Service and Repair/Refrigerant - Recovery 2. Lift the vehicle on an approved hoist. 3. Remove the passenger side rear tire. 4. Remove the passenger side rear inner fender well. 5. Disconnect the rear a/c lines from the rear evaporator. 6. Mark cut location on tube on vehicle. 7. Cut tube on truck. 8. Size replacement tube, same as tube removed from truck. 9. Scuff end of both tubes using pad provide in special tool kit. 10. Select proper Lokring for 5/8" tube. 11. Put a drop of sealer from kit on the end of each tube, install Lokring and rotate to spread sealer evenly. 12. Select the proper jaws for the installation tool (5/8") from the kit. 13. Put installation tool over the Lokring with tubes installed (tubes must be bottomed out in Lokring). 14. Compress Lokring using a wrench to draw the screw tight on the installation tool. Tighten the tool until the Lokring is bottomed out. 15. Backoff the screw and remove the installation tool. 16. Reconnect the rear evaporator. 17. Install the passenger side inner fender. 18. Install the passenger side tire. 19. Lower the vehicle. 20. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant Evacuate, See: Fluids/Refrigerant/Service and Repair/Refrigerant - Evacuate 21. Recharge the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Charge, See: Fluids/Refrigerant/Service and Repair/Refrigerant - Charge 3/8" Rear A/C Tube Repair 1. Evacuate and recover the refrigerant from the a/c system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Recovery, See: Fluids/Refrigerant/Service and Repair/Refrigerant - Recovery 2. Lift vehicle on an approved hoist. 3. Remove the rear passenger side tire. 4. Remove the rear passenger side inner wheel well. 5. Disconnect the rear a/c line from the rear evaporator. 6. Mark cut location on tube on vehicle. 7. Cut tube on truck. 8. Size replacement tube, same as tube removed from the truck. 9. Scuff end of both tubes using pad provide in special tool kit. 10. Select proper Lokring for 3/8" tube. 11. Put a drop of sealer from kit on the end of each tube, install Lokring and rotate to spread sealer evenly. 12. Select the proper jaws for the installation tool (3/8") from the special tool kit. 13. Put installation tool over the Lokring with tubes installed. 14. Compress Lokring using a wrench to draw the screw tight on the installation tool. Tighten the tool until the Lokring is bottomed out. 15. Back off the screw and remove the installation tool. 16. Reconnect the rear evaporator. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1083 17. Install the passenger side inner fender well. 18. Install the passenger side rear tire. 19. Lower the vehicle from the hoist. 20. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Evacuate, See: Fluids/Refrigerant/Service and Repair/Refrigerant - Evacuate 21. Recharge the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Charge, See: Fluids/Refrigerant/Service and Repair/Refrigerant - Charge INSTALLATION Complete Rear A/C Line 1. Install the complete a/c line assembly into the vehicle. 2. Install the a/c line brackets that will not be accessible once body is lowered onto frame. 3. Raise the hoist until the frame and body are lined up and the body mounts line up with the frame mounting pieces. 4. Install all remaining underbody a/c line assembly brackets. 5. Install all body mount bolts on the passenger side and tighten both passenger and drive side mount bolts. 6. Raise the lift until the jack stands are free, then remove the jack stands from under the vehicle. 7. Connect the underbody a/c lines at the rear HVAC unit. 8. Connect the front a/c lines in the engine compartment. 9. Install the front and rear inner fenders. 10. Install passenger side tires. 11. Lower vehicle on lift. 12. Install air box. 13. Evacuate refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant Evacuate, See: Fluids/Refrigerant/Service and Repair/Refrigerant - Evacuate 14. Charge refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Charge, See: Fluids/Refrigerant/Service and Repair/Refrigerant - Charge Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1084 Hose/Line HVAC: Service and Repair Rear Underbody Heater Lines Replacement REMOVAL 1/2" Front Heater Tube Repair 1. Pinch hoses in engine compartment using spring clamp pliers. 2. Remove air box. 3. Remove passenger front tire. 4. Remove front inner fender well. 5. Disconnect the heater hose from underbody heater line using constant tension clamp pliers. 6. Drain coolant from underbody heater lines into an approved container. 7. Remove line brackets as necessary. 8. Mark cut location on tube on vehicle. 9. Cut tube on vehicle. 10. Size replacement tube, same as tube removed from vehicle. 11. Scuff end of both tubes using pad provided in special tool kit. 12. Select proper Lokring for 1/2" tube. 13. Put a drop of sealer from kit in the end of each tube, install Lokring and rotate to spread sealer evenly. 14. Select the proper jaws for the installation tool 1/2" from the kit. 15. Put installation tool over the Lokring with tubes installed (tube must be bottomed out in Lokring). 16. Compress Lokring using a wrench to draw the screw tight on the installation tool. Tighten the tool until the Lokring is bottomed out. 17. Back off the screw and remove the installation tool. 18. Reconnect the heater hose to the heater line. 19. Fill the cooling system. 20. Reinstall the front inner fender well. 21. Reinstall the front passenger side tire. 22. Reinstall the air box. Complete Heater Line 1. Drain the cooling system. 2. Remove the air box. 3. Lift vehicle on hoist. 4. Remove passenger side tires. 5. Remove both front and rear inner fenders. 6. Disconnect the underhood heater lines using spring clamp release pliers. 7. Disconnect the rear heater lines at the rear heat core connections using spring clamp pliers. 8. Remove all body mount bolts on the passenger side and loosen the body mount bolts on the driver side. 9. Place a jack stand at the front and rear of the vehicle on the passenger side so that the stands will support the body. 10. Detach all underbody heater line brackets from the body that are accessible. 11. Lower the hoist until the body, that is being supported by the stands, is approximately 3-4 inches above the frame. This will allow access to the underbody assembly. 12. Remove all remaining heater line brackets that were not accessible before the body lift. 13. Remove the complete heater line assembly from the vehicle. 1/2" Rear Heater Tube Repair 1. Remove and isolate the battery negative cable from the battery. 2. Drain the cooling system. 3. Lift vehicle on hoist. 4. Pinch heater hoses in engine compartment. 5. Remove rear passenger tire. 6. Remove rear inner fender well. 7. Disconnect the heater hose from the rear heater core using constant tension clamp pliers. 8. Drain any remaining coolant from the underbody heater lines and rear heater core. 9. Mark cut location on tube on vehicle. 10. Cut tube on vehicle. 11. Size replacement tube, same size as tube removed from vehicle. 12. Scuff end of both tubes using pad provide in special tool kit. 13. Select proper Lokring for tube. 14. Put a drop of sealer from kit on the end of each tube, install Lokring and rotate to spread sealer evenly. 15. Put installation tool over the Lokring with tubes installed (tubes must be bottomed out in Lokring) 16. Select the proper jaws for the installation tool from the kit. 17. Compress Lokring using a wrench to draw the screw tight on the installation tool. Tighten the tool until the Lokring is bottomed out. 18. Connect the heater hose to the rear heater core using constant tension clamp pliers. 19. Install the rear inner fender well. 20. Install the passenger tire. 21. Remove the hose clamp from the heater hoses in the engine compartment. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1085 22. Lower the vehicle on the hoist. 23. Refill the cooling system. 24. Connect the battery negative cable to the battery. INSTALLATION Complete Heater Line 1. Install the complete heater line assembly to the vehicle. 2. Install all heater line brackets that were not accessible before body lift. 3. Raise the hoist until the frame and body are lined up and the body mounts line up with the frame mounting pieces. 4. Install all remaining underbody heater line assembly brackets. 5. Install all body mount bolts on the passenger side and tighten both the passenger and driver side mount bolts. 6. Raise the lift until the jack stands are free, then remove the jack stands from under the vehicle. 7. Connect the underbody heater lines at the rear heater core. 8. Connect the front underhood heater lines using spring clamp pliers. 9. Install the front and rear inner fenders. 10. Install the passenger side tires. 11. Lower the vehicle on the lift. 12. Install the air box. 13. Refill the cooling system. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Power Steering Line Pressure Line 25 ft.lb Return Line 25 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Pressure Power Steering Line/Hose: Service and Repair Hose - Pressure REMOVAL - PRESSURE HOSE 1. Siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the pressure hose at the pump. 4. Disconnect the pressure hose at the gear. 5. Remove the pressure hose from the vehicle. INSTALLATION - PRESSURE HOSE 1. Install the pressure hose to the vehicle. 2. Reconnect the pressure hose at the gear. Tighten the hose to 34 Nm (25 ft. lbs.). 3. Reconnect the pressure hose at the pump. Tighten the hose to 34 Nm (25 ft. lbs.). 4. Remove the support and lower the vehicle. 5. Refill the power steering system. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Pressure > Page 1091 Power Steering Line/Hose: Service and Repair Hose - Return REMOVAL - RETURN HOSE 1. Siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the return hose at the cooler. 4. Disconnect the return hose at the gear. 5. Remove the return hose from the vehicle. INSTALLATION - RETURN HOSE 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. Tighten the hose to 34 Nm (25 ft. lbs.). 3. Reconnect the return hose at the gear. Tighten the hose to 34 Nm (25 ft. lbs.). 4. Remove the support and lower the vehicle. 5. Refill the power steering system. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications BRAKE FLUID Specification ........................................................................................................................................ .................................................................. DOT 3 Standard .............................................................................................................................................. ........................................................... SAE J1703 NOTE: The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1096 Brake Fluid: Service Precautions SAFETY PRECAUTIONS WARNING: Brake fluid may be irritating to the skin or eyes. In case of contact, take the following actions: * Eye Contact - rinse eyes thoroughly with water. * Skin Contact - wash skin with soap and water. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1097 Brake Fluid: Testing and Inspection DIAGNOSIS AND TESTING - BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swollen rubber parts indicate the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If brake fluid is contaminated, drain and thoroughly flush system. Replace master cylinder, proportioning valve, caliper seals, wheel cylinder seals, Antilock Brakes hydraulic unit and all hydraulic fluid hoses. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Mechanical Specifications Coolant: Mechanical Specifications Coolant 13.0 qt (US) Nominal refill capacities are shown. A variation may be observed vehicle due to manufacturing tolerances and refill procedures. Capacities shown include vehicles with air conditioning and/or heavy duty cooling system. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Mechanical Specifications > Page 1102 Coolant: Capacity Specifications Coolant Capacity With Out Rear Heat ............................................................................................................................. .......................................... 12.6 Liters ( 13.3 qts ) With Rear Heat ..................................................... ......................................................................................................................... 13.4 Liters ( 14.1 qts ) Note: Includes 0.9 Liters ( 1.0 qts ) for coolant reservoir. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Mechanical Specifications > Page 1103 Coolant: Fluid Type Specifications This vehicle has been factory filled with an Ethylene Glycol based engine coolant with long life corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology). When it becomes necessary to replace the coolant, Use a coolant like Mopar Antifreeze/Coolant, 5 year/100,000 mile formula (MS-9769), P/N 5011764AB or equivalent. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1104 Coolant: Service Precautions DO NOT mix green colored coolant with orange colored coolant. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1109 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1110 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1111 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1112 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1113 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid Capacity Model 42RE, 44RE, 46RE ................................................................................................................... ............................................ 9.1-9.5Liters (19-20 Pt) Model 45RFE ....................................................................................................................................... ................................................. 13.33Liters (28.0 Pt) Capacities may vary. Check fluid level on dipstick according to applicable procedures. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1116 Fluid - A/T: Fluid Type Specifications A/T Fluid Type Model 42RE, 46RE, 45RFE ...................................................................................................................................................... Mopar ATF + 4, Type 9602 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1117 Fluid - A/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Effects of Incorrect Fluid Level Fluid - A/T: Testing and Inspection Effects of Incorrect Fluid Level EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be low and develop slower than normal. If the transmission is overfilled, the gears chum the fluid into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid overheating, oxidation and varnish buildup which interferes with valve and clutch operation. Foaming also causes fluid expansion which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Effects of Incorrect Fluid Level > Page 1120 Fluid - A/T: Testing and Inspection Causes of Burnt Fluid CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has three primary causes. 1. Internal clutch slippage, usually caused by low line pressure, inadequate clutch apply pressure, or clutch seal failure. 2. A result of restricted fluid flow through the main and/or auxiliary cooler. This condition is usually the result of a faulty or improperly installed drainback valve, a damaged main cooler, or severe restrictions in the coolers and lines caused by debris or kinked lines. 3. Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to handle heavy loads. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Effects of Incorrect Fluid Level > Page 1121 Fluid - A/T: Testing and Inspection Fluid Contamination FLUID CONTAMINATION Transmission fluid contamination is generally a result of: - adding incorrect fluid - failure to clean dipstick and fill tube when checking level - engine coolant entering the fluid - internal failure that generates debris - overheat that generates sludge (fluid breakdown) - failure to reverse flush cooler and lines after repair - failure to replace contaminated converter after repair The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary. The transmission cooler and lines should be reverse flushed whenever a malfunction generates sludge and/or debris. The torque converter should also be replaced at the same time. Failure to flush the cooler and lines will result in recontamination. Flushing applies to auxiliary coolers as well. The torque converter should also be replaced whenever a failure generates sludge and debris. This is necessary because normal converter flushing procedures will not remove all contaminants. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check Fluid - A/T: Service and Repair Fluid Level Check FLUID LEVEL CHECK Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmission has too much fluid, the geartrain churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. Along with fluid level, it is important to check the condition of the fluid. When the fluid smells burned, and is contaminated with metal or friction material particles, a complete transmission recondition is needed. Be sure to examine the fluid on the dipstick closely. If there is any doubt about its condition, drain out a sample for a double check. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. The transmission has a dipstick to check oil level. It is located on the right side of the engine. Be sure to wipe all dirt from dipstick handle before removing. The torque converter fills in both the P (PARK) and N (NEUTRAL) positions. Place the selector lever in P (PARK) to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature (approximately 82°C. or 180°F.), the fluid level is correct if it is in the HOT region (cross-hatched area) on the oil level indicator. The fluid level will be approximately at the upper COLD hole of the dipstick at 70°F fluid temperature. NOTE: Engine and Transmission should be at normal operating temperature before performing this procedure. 1. Start engine and apply parking brake. 2. Shift the transmission into DRIVE for approximately 2 seconds. 3. Shift the transmission into REVERSE for approximately 2 seconds. 4. Shift the transmission into PARK. 5. Hook up DRB@ scan tool and select transmission. 6. Select sensors. 7. Read the transmission temperature value. 8. Compare the fluid temperature value with the chart. 9. Adjust transmission fluid level shown on the dipstick according to the chart. NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the transmission before rechecking the fluid level. 10. Check transmission for leaks. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check > Page 1124 Fluid - A/T: Service and Repair Fluid and Filter Service STANDARD PROCEDURE - FLUID AND FILTER REPLACEMENT REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission. 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolts holding pan to transmission. 7. While holding pan level, lower pan away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove screw holding filter to valve body (Fig. 54). 10. Separate filter from valve body and oil pump and pour fluid in filter into drain pan. 11. Remove and discard the oil filter seal from the bottom of the oil pump. 12. If replacing the cooler return filter, use Oil Filter Wrench 8321 to remove the filter from the transmission. 13. Dispose of used trans fluid and filter(s) properly. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check > Page 1125 Transmission Fluid Temperature Chart INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION 1. Install a new oil filter seal into the bottom of the oil pump. NOTE: Do not attempt to install the seal onto the oil filter first and then into the oil pump. An unsatisfactory seal between the oil pump and filter will result, allowing air to be drawn into the pump. 2. Place replacement filter in position on valve body and into the oil pump. 3. Install screw to hold filter to valve body (Fig. 54). Tighten screw to 4.5 Nm (40 inch lbs.) torque. 4. Install new cooler return filter onto the transmission, if necessary. Torque the filter to 14.12 Nm (125 inch lbs.). 5. Place bead of Mopar(R) RTV sealant onto the transmission case sealing surface. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 11.8 Nm (105 inch lbs.) torque. 8. Lower vehicle and fill transmission with Mopar(R) ATF +4, type 9602 fluid. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check > Page 1126 Fluid - A/T: Service and Repair Transmission Fill TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar(R) ATF +4 to transmission: a. If only fluid and filter were changed, add 10 pints (5 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled, torque converter was replaced or drained, and cooler was flushed, add 24 pints (12 quarts) of ATF +4 to transmission. 3. Check the transmission fluid and adjust as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service Precautions Fluid - M/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications DIFFERENTIAL FLUID CAPACITY C205F .................................................................................................................................................. .................................................... 1.66Liters (3.5 pts) 8 1/4 AA ............................................................................................................................................... ................................................... 2.22Liters (4.7 pts) With Trac-Lok include 5.0 oz of friction modifier 9 1/4 ..................................................................................................................................................... .................................................... 2.32Liters (4.9 pts) With Trac-Lok include 5.0 oz of friction modifier Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1134 Fluid - Differential: Fluid Type Specifications Rear Differential 8 1/4" ................................................................................................................................................... ......................................... Thermally Stable 80W-90 9 1/4" ................................................................ ............................................................................................................................ Thermally Stable 75W-90 Note: Vehicles equipped with Trac-Lok limited slip differential requires use of friction modifier. Front Differential Thermally Stable 80W-90. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Page 1135 Fluid - Differential: Service Precautions DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Additives/Supplements Engine Oil: Technical Service Bulletins Engine Oil - Additives/Supplements NUMBER: 09-003-01 GROUP: Engine DATE: May 4, 2001 SUBJECT: Engine Oil Additives/Supplements OVERVIEW: This bulletin reinforces a requirement to cease the current practice of using supplemental oil additive treatments in all DaimlerChrysler engines. MODELS: 2001 (AB) Ram Van/Wagon 2001 (AN) Dakota 2001 (BR/BE) Ram Pickup 2001 (DN) Durango 2001 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 2002 (KJ) Liberty 2001 (LH) Concorde/Intrepid/LHS/300M 2001 (PL) Neon 2001 (PR) Prowler 2001 (PT) PT Cruiser 2001 (RG) Chrysler Voyager (International Markets) 2001 (RS) Town & Country/Caravan/Voyager 2001 (ST) Sebring Coupe 2001 (SR) Viper 2001 (TJ) Wrangler 2001 (WG) Grand Cherokee (International Markets) 2001 (WJ) Grand Cherokee 2001 (XJ) Cherokee NOTE: THIS BULLETIN APPLIES TO ALL DAIMLERCHRYSLER MODELS/ENGINES BUILT BEFORE AND AFTER THE 2001 MODEL YEAR. DISCUSSION Engine oil additives/supplements (EOS) should not be used to enhance engine oil performance. Engine oil additives/supplements should not be used to extend engine oil change intervals. No additive is known to be safe for engine durability and can degrade emission components. Additives can contain undesirable materials that harm the long term durability of engines by: ^ Doubling the level of Phosphorus in the engine oil. The ILSAC (International Lubricant Standard Approval Committee) GF-2 and GF-3 standards require that engine oil contain no more than 0.10% Phosphorus to protect the vehicles emissions performance. Addition of engine oil additives/supplements can poison, from the added sulfur and phosphorus, catalysts and hinder efforts to guarantee our emissions performance to 80,000 miles and new requirements of 150,000 miles. ^ Altering the viscosity characteristics of the engine oil so that it no longer meets the requirements of the specified viscosity grade. ^ Creating potential for an undesirable additive compatibility interaction in the engine crankcase. Generally it is not desirable to mix additive packages from different suppliers in the crankcase; there have been reports of low temperature engine failures caused by additive package incompatibility with such mixtures. POLICY: Information Only Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil Capacity w/filter .................................................................................................................. ....................................................................... 6.0 Qt Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1142 Engine Oil: Fluid Type Specifications Engine Oil Type ................................................................................................................................... ................................... 5W-30 SAE or 10W-30 SAE Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1143 Engine Oil: Service Precautions SAFETY PRECAUTIONS WARNING: Prolonged and repeated contact with used engine oil may cause skin cancer. Avoid prolonged and repeated contact with oils, particularly used engine oils. - Wear protective clothing, including impervious gloves where practicable. - Do not put oily rags in pockets. - Avoid contaminating clothes, particularly underpants, with oil. - Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly. - First Aid treatment should be obtained immediately for open cuts and wounds. - Use barrier creams, applying them before each work period, to help the removal of oil from the skin. - Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. - Do not use gasoline, kerosine, diesel fuel, gas oil, thinner or solvents for cleaning skin. - If skin disorders develop, obtain medical advice without delay. - Where practicable, degrease components prior to handling. - Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1144 Engine Oil: Service and Repair STANDARD PROCEDURE - ENGINE OIL SERVICE WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER. DO NOT WASH SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. ENGINE OIL SPECIFICATION CAUTION: Do not use non-detergent or straight mineral oil when adding or changing crankcase lubricant. Engine failure can result. API SERVICE GRADE CERTIFIED Use an engine oil that is API Service Grade Certified. MOPAR provides engine oils that conform to this service grade. SAE VISCOSITY An SAE viscosity grade is used to specify the viscosity of engine oil. Use only engine oils with multiple viscosities such as 5W-30 or 1OW-30 in the 4.7L engines. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your particular temperature range and variation (Fig. 97). ENERGY CONSERVING OIL An Energy Conserving type oil is recommended for gasoline engines. The designation of ENERGY CONSERVING is located on the label of an engine oil container. CONTAINER IDENTIFICATION Standard engine oil identification notations have been adopted to aid in the proper selection of engine oil. The identifying notations are located on the label of engine oil plastic bottles and the top of engine oil cans (Fig. 98). OIL LEVEL INDICATOR (DIPSTICK) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1145 The engine oil level indicator is located at the right rear of the engine on the 4.7L engines. (Fig. 99). CRANKCASE OIL LEVEL INSPECTION CAUTION: Do not overfill crankcase with engine oil, pressure loss or oil foaming can result. Inspect engine oil level approximately every 800 kilometers (500 miles). Unless the engine has exhibited loss of oil pressure, run the engine for about five minutes before checking oil level. Checking engine oil level on a cold engine is not accurate. To ensure proper lubrication of an engine, the engine oil must be maintained at an acceptable level. The acceptable levels are indicated between the ADD and SAFE marks on the engine oil dipstick. 1. Position vehicle on level surface. 2. With engine OFF, allow approximately ten minutes for oil to settle to bottom of crankcase, remove engine oil dipstick. 3. Wipe dipstick clean. 4. Install dipstick and verify it is seated in the tube. 5. Remove dipstick, with handle held above the tip, take oil level reading. 6. Add oil only if level is below the ADD mark on dipstick. ENGINE OIL CHANGE Change engine oil at mileage and time intervals described in Maintenance Schedules. Run engine until achieving normal operating temperature. 1. Position the vehicle on a level surface and turn engine off. 2. Hoist and support vehicle on safety stands. 3. Remove oil fill cap. 4. Place a suitable drain pan under crankcase drain. 5. Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug if damaged. 6. Install drain plug in crankcase. 7. Lower vehicle and fill crankcase with specified type and amount of engine oil. 8. Install oil fill cap. 9. Start engine and inspect for leaks. 10. Stop engine and inspect oil level. USED ENGINE OIL DISPOSAL Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 1150 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 1151 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 1152 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1153 Power Steering Fluid: Specifications All models Mopar Power Steering Fluid or equivalent Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1154 Power Steering Fluid: Service Precautions DO NOT use automatic transmission fluid instead of Mopar Power Steering Fluid. System damage can result. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Information not supplied by the manufacturer Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1159 Refrigerant: Fluid Type Specifications HydroFluoroCarbon (HFC), ....................................................................................................................................................... R-134a liquified freon gas Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1160 Refrigerant: Service Precautions R-134a - R-12 Because R-134a refrigerant is a hydrofluorocarbon (HFC) which contains hydrogen atoms in place of chlorine atoms, it will not cause damage to the ozone layer. Ozone filters out harmful radiation from the sun. To assist in protecting the ozone layer, Chrysler Corporation recommends an R-134a refrigerant recycling device. The Clean Air Act Amendment of 1990 requires that Freon be recovered when accessing the air conditioning circuit and that technicians hold a refrigerant recovery and handling certification. The Ozone Layer A thin layer of ozone molecules, located 10 to 30 miles above the earth, form a protective cover by absorbing a portion of the ultraviolet (UV) radiation emitted from the Sun. Ozone Depletion Scientific research performed over the past 15 years links the release of chlorofluorocarbons (CFC)s, also know by the trade name Freon) into the atmosphere to ozone depletion. When CFCs are released into the atmosphere, they eventually reach the ozone layer located in the stratosphere where they react with and destroy ozone molecules. Harmful Effects Ozone depletion and the corresponding increase in UV radiation has been shown to lead to higher incidents of cancer as well as global warming. When viewed from a global perspective, ozone depletion holds an enormous potential for damage. Upper Level vs. Ground Level Ozone Confusion often arises when we hear about the necessity of the ozone layer and ground level ozone. The ozone layer existing high above the earth is beneficial but the same compound, when located at ground level, is harmful to humans, animals, crops and vegetation. Ground level ozone is a component of smog and forms when hydrocarbons (HC) react with nitrogen oxides (NOx) in the presence of sunlight and heat. Montreal Protocol In response to the growing body of evidence demonstrating the detrimental effects of (CFC)s, 24 countries and the European community met in Montreal, Canada, in 1987 to establish standards for the control of (CFC)s. Since that time, a total of 132 countries have become signatories to this agreement leading to an end of production of R12 in December, 1995, in all developed countries. As established by the Montreal Protocol, R12 production in developed countries has ceased. Clean Air Act The United States Congress, acting in response to the Montreal Protocol, banned production of (CFC)s by the year 2000. Congress also amended the Clean Air Act in an effort to control both the production and use of (CFC)s for refrigerant applications including mobile vehicle air conditioning systems. Technician Certification Organizations providing technician refrigerant recovery and recycling certification include: National Institute for Automotive Service Excellence (ASE) 13505 Dulles Technology Drive, Suite 2 Herndon, VA 22071-3421 Phone: (703) 713-3800 Fax: (703) 713-0727 http://www.asecert.org/ International Mobile Air Conditioning Association (IMACA) P.O. Box 9000 Fort Worth, TX 76147-2000 Phone: (817) 338-1100 Fax: (817) 338-1451 Mobile Air Conditioning Society (MACS) Worldwide P.O. Box 100 East Greenville, PA 18041 Phone: 215-679-2220 Fax: 215-541-4635 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1161 http://www.macsw.org/ Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1162 Refrigerant: Description and Operation REFRIGERANT The refrigerant used in this air conditioning system is a HydroFluoroCarbon (HFC), type R-134a. Unlike R-12, which is a ChloroFluoroCarbon (CFC), R-134a refrigerant does not contain ozone-depleting chlorine. R-134a refrigerant is a non-toxic, non-Hammable, clear, and colorless liquefied gas. Even though R-134a does not contain chlorine, it must be reclaimed and recycled just like CFC-type refrigerants. This is because R-134a is a greenhouse gas and can contribute to global warming. R-134a refrigerant is not compatible with R-12 refrigerant in an air conditioning system. Even a small amount of R-12 added to an R-134a refrigerant system will cause compressor failure, refrigerant oil sludge or poor air conditioning system performance. In addition, the PolyAlkylene Glycol (PAG) synthetic refrigerant oils used in an R-134a refrigerant system are not compatible with the mineral-based refrigerant oils used in an R-12 refrigerant system. R-134a refrigerant system service ports, service tool couplers and refrigerant dispensing bottles have all been designed with unique fittings to ensure that an R-134a system is not accidentally contaminated with the wrong refrigerant (R-12). There are also labels posted in the engine compartment of the vehicle and on the compressor identifying to service technicians that the air conditioning system is equipped with R-134a. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1163 Refrigerant: Testing and Inspection If the air conditioning system does not cool properly, the A/C system performance should be tested. See A/C Performance for the procedures. If the A/C system refrigerant fill is found to be low or if the system is empty; a leak at a refrigerant line, connector fitting, component, or component seal is likely. An electronic leak detector designed for R-134a refrigerant, or a fluorescent R-134a leak detection dye and a black light are recommended for locating and confirming refrigerant system leaks. Refer to the operating instructions supplied by the equipment manufacturer for the proper care and use of this equipment. NOTE: A/C SYSTEM ALREADY CONTAINS A FACTORY INSTALLED FLUORESCENT DYE. An oily residue on or near refrigerant system lines, connector fittings, components, or component seals can indicate the general location of a possible refrigerant leak. However, the exact leak location should be confirmed with an electronic leak detector prior to component repair or replacement. To detect a leak in the refrigerant system with an electronic leak detector, perform one of the following procedures: SYSTEM EMPTY 1. Evacuate the refrigerant system. 2. Connect and dispense 0.283 kilograms (0.625 pounds or 10 ounces) of R-134a refrigerant into the evacuated refrigerant system. 3. Position the vehicle in a wind-free work area. This will aid in detecting small leaks. 4. With the engine not running, use an electronic R-134a leak detector and search for leaks. Because R-134a refrigerant is heavier than air, the leak detector probe should be moved slowly along the bottom side of all refrigerant lines, connector fittings and components. 5. To inspect the front evaporator coil for leaks, insert the electronic leak detector probe into the center instrument panel outlet and the floor duct outlet. Set the front blower motor switch to the lowest speed position, and the mode control switch to the recirculation mode (Max-A/C). 6. To inspect for leaks in the rear evaporator, put the rear system in the floor mode and place the probe in the rear unit floor outlet. SYSTEM LOW 1. Position the vehicle in a wind-free work area. This will aid in detecting small leaks. 2. Bring the refrigerant system up to operating temperature and pressure. This is done by allowing the engine to run with the air conditioning system turned on for five minutes. 3. With the engine not running, use an electronic R-134a leak detector and search for leaks. Because R-134a refrigerant is heavier than air, the leak detector probe should be moved slowly along the bottom side of all refrigerant lines, connector fittings and components. 4. To inspect the evaporator coil for leaks, insert the electronic leak detector probe into the center instrument panel outlet and the floor duct outlet. Set the front blower motor switch to the lowest speed position, and the mode control switch to the recirculation mode (Max-A/C). 5. To detect a leak in the rear evaporator, put the rear system in the floor mode and place the probe in the rear unit floor outlet. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant - Recovery Refrigerant: Service and Repair Refrigerant - Recovery A R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J22 10 must be used to recover the refrigerant from an R-134a refrigerant system. Refer to the operating instructions supplied by the equipment manufacturer for the proper care and use of this equipment. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant - Recovery > Page 1166 Refrigerant: Service and Repair Refrigerant - Evacuate If the refrigerant system has been open to the atmosphere, it must be evacuated before the system can be charged. If moisture and air enters the system and becomes mixed with the refrigerant, the compressor head pressure will rise above acceptable operating levels. This will reduce the performance of the air conditioner and damage the compressor. Evacuating the refrigerant system will remove the air and boil the moisture out of the system at near room temperature. To evacuate the refrigerant system, use the following procedure: 1. Connect a R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 and a manifold gauge set to the refrigerant system of the vehicle. 2. Open the low and high side valves and start the charging station vacuum pump. When the suction gauge reads 88 kPa (26 in. Hg.) vacuum or greater, close all of the valves and turn OFF the vacuum pump. a. If the refrigerant system fails to reach the specified vacuum, the system has a leak that must be corrected. See Refrigerant System Leaks in the Diagnosis and Testing for the procedures. b. If the refrigerant system maintains the specified vacuum for five minutes, restart the vacuum pump, open the suction and discharge valves and evacuate the system for an additional ten minutes. 3. Close all of the valves, and turn OFF the charging station vacuum pump. 4. The refrigerant system is now ready to be charged with R-134a refrigerant. See Refrigerant System Charge in the Service Procedures. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant - Recovery > Page 1167 Refrigerant: Service and Repair Refrigerant - Charge The R-134a refrigerant system charge capacity for this vehicle can be found on the underhood A/C specification sheet. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Total System Front .................................................................................................................................................... ...................................................... 210 ml (7.1 oz.) Front & Rear ....................................................... ..................................................................................................................................... 300 ml (10.1 oz.) Filter-Drier ............................................................................................................................................ ............................................................. 30 ml (1 oz.) Condenser ........................................................................................................................................... ................................................................ 30 ml (1 oz.) Evaporator Front .................................................................................................................................................... ........................................................... 60 ml (2 oz.) Rear .................................................................... ............................................................................................................................................ 30 ml (1 oz.) Compressor ......................................................................................................................................... ...................................................................... See Note Note: When replacing the A/C compressor, drain and measure the amount of oil from the old compressor. Add the equivalent amount of fresh oil to the new compressor. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1172 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil Type ............................................................................................................................ ............................................................... SP-15 PAG Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1173 Refrigerant Oil: Service and Repair REFRIGERANT OIL - FRONT The refrigerant oil used in R-134a refrigerant systems is a synthetic-based, PolyAlkylene Glycol (PAG), wax-free lubricant. Mineral-based R-12 refrigerant oils are not compatible with PAG Oils and should never be introduced to an R-134a refrigerant system. There are different PAG oils available, and each contains a different additive package. The SD7H15 compressor used in this vehicle is designed to use an SP-20 PAG refrigerant oil. Use only refrigerant oil of this same type to service the refrigerant system. After performing any refrigerant recovery or recycling operation, always replenish the refrigerant system with the same amount of the recommended refrigerant oil as was removed. Too little refrigerant oil can cause compressor damage, and too much can reduce air conditioning system performance. PAG refrigerant oil is much more hygroscopic than mineral oil, and will absorb any moisture it comes into contact with, even moisture in the air. The PAG oil container should always be kept tightly capped until it is ready to be used. After use, recap the oil container immediately to prevent moisture contamination. REFRIGERANT OIL LEVEL - FRONT When an air conditioning system is assembled at the factory, all components except the compressor are refrigerant oil free. After the refrigerant system has been charged and operated, the refrigerant oil in the compressor is dispersed throughout the refrigerant system. The evaporator, filter-drier, condenser, and compressor will each retain a significant amount of the needed refrigerant oil. It is important to have the correct amount of oil in the refrigerant system. This ensures proper lubrication of the compressor. Too little oil will result in damage to the compressor. Too much oil will reduce the cooling capacity of the air conditioning system. It will not be necessary to check the oil level in the compressor or to add oil, unless there has been an oil loss. An oil loss may occur due to a rupture or leak from a refrigerant line, a connector fitting, a component, or a component seal. If a leak occurs, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system after the repair has been made. Refrigerant oil loss will be evident at the leak point by the presence of a wet, shiny surface around the leak. Refrigerant Oil Capacities Chart Refrigerant oil must be added when a filter-drier, evaporator coil, or condenser are replaced. See the Refrigerant Oil Capacities chart. When a compressor is replaced, the refrigerant oil must be drained from the old compressor and measured. Drain all of the refrigerant oil from the new compressor, then fill the new compressor with the same amount of refrigerant oil that was drained out of the old compressor. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding Brake Bleeding: Service and Repair Master Cylinder Bleeding STANDARD PROCEDURE - MASTER CYLINDER BLEEDING A new master cylinder should be bled before installation on the vehicle. Required bleeding tools include bleed tubes and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from brake line. (1) Mount master cylinder in vise. Master Cylinder Bleeding - Typical (2) Attach bleed tubes to cylinder outlet ports. Then position each tube end into the reservoir. (3) Fill reservoir with fresh brake fluid. (4) Press cylinder pistons inward with wood dowel. Then release pistons and allow them to return under spring pressure. Continue bleeding operations until air bubbles are no longer visible in fluid Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 1178 Brake Bleeding: Service and Repair Standard Procedure - Manual Bleeding STANDARD PROCEDURE - MANUAL BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. 1. Remove reservoir filler caps and fill reservoir. 2. If calipers, or wheel cylinders were overhauled, open all caliper and wheel cylinder bleed screws. Then close each bleed screw as fluid starts to drip from it. Top off master cylinder reservoir once more before proceeding. 3. Attach one end of bleed hose to bleed screw and insert opposite end in glass container partially filled with brake fluid. Be sure end of bleed hose is immersed in fluid. 4. Open up bleeder, then have a helper press down the brake pedal. Once the pedal is down close the bleeder. Repeat bleeding until fluid stream is clear and free of bubbles. Then move to the next wheel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 1179 Brake Bleeding: Service and Repair Standard Procedure - Pressure Bleeding STANDARD PROCEDURE - PRESSURE BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Generally, a tank pressure of 15 - 20 psi is sufficient for bleeding. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding. Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system. Use adapter provided with the equipment or Adapter 6921. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 1183 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions Circuit Breaker: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1189 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1190 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1191 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1192 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1193 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1194 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1195 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1196 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1197 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1198 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1199 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1200 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1201 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1202 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1203 Circuit Breaker: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1204 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1205 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1206 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1207 Circuit Breaker: Electrical Diagrams 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1208 8w-12-3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1209 8w-12-5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Page 1210 Circuit Breaker: Description and Operation An automatic resetting circuit breaker in the junction block is used to protect the power seat system circuit. The circuit breaker can protect the system from a short circuit, or from an overload condition caused by an obstructed or stuck seat adjuster. The circuit breaker cannot be repaired and, if faulty or damaged, it must be replaced. An automatic resetting circuit breaker in the junction block is used to protect the power window system circuit. The circuit breaker can protect the system from a short circuit, or from an overload condition caused by an obstructed or stuck window glass or regulator. The circuit breaker cannot be repaired and, if faulty, it must be replaced. 1. Locate the correct circuit breaker in the junction block. Pull out the circuit breaker slightly, but be certain that the circuit breaker terminals still contact the terminals in the junction block cavities. 2. Connect the negative lead of a 12-volt DC voltmeter to a good ground. 3. With the voltmeter positive lead, check both terminals of the circuit breaker for battery voltage. If only one terminal has battery voltage, the circuit breaker is faulty and must be replaced. If neither terminal has battery voltage, repair the open circuit from the Power Distribution Center (PDC) as required. 1. Locate the circuit breaker in the junction block. Pull out the circuit breaker slightly, but be certain that the circuit breaker terminals still contact the terminals in the junction block cavities. 2. Connect the negative lead of a 12-volt DC voltmeter to a good ground. 3. With the voltmeter positive lead, check both terminals of the circuit breaker for battery voltage. If only one terminal has battery voltage, the circuit breaker is faulty and must be replaced. If neither terminal has battery voltage, repair the open circuit from the Power Distribution Center (PDC) as required. If the circuit breaker checks OK, but no power windows operate, see Power Window System in the Diagnosis and Testing. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Junction Block Fuse: Locations Junction Block Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Junction Block > Page 1215 Fuse: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block Fuse: Diagrams Junction Block 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1218 8w-12-3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1219 8w-12-4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1220 8w-12-5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1221 Junction Block C1 Junction Block C2 Junction Block C3 Junction Block C4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1222 Junction Block C5 Junction Block C6 Junction Block C7 Junction Block C8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1223 Junction Block C9 Junction Block C10 Junction Block C11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1224 Junction Block C12 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1225 Fuse: Diagrams Power Distribution Center 8w-10-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1226 8w-10-3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1227 8w-10-4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1228 8w-10-5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1229 8w-10-6 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1230 8w-10-7 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1231 8w-10-8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1232 8w-10-9 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1233 8w-10-10 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1234 8w-10-11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1235 8w-10-12 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Junction Block Fuse: Application and ID Junction Block Junction Block Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Junction Block > Page 1238 Fuse: Application and ID Power Distribution Center Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Junction Block Fuse Block: Locations Junction Block Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Junction Block > Page 1243 Fuse Block: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1246 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1247 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1248 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1249 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1250 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1251 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1252 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1253 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1254 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1255 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1256 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1257 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1258 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1259 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1260 Fuse Block: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1261 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1262 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1263 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1264 Fuse Block: Connector Views Junction Block 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1265 8w-12-3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1266 8w-12-4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1267 8w-12-5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1268 Junction Block C1 Junction Block C2 Junction Block C3 Junction Block C4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1269 Junction Block C5 Junction Block C6 Junction Block C7 Junction Block C8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1270 Junction Block C9 Junction Block C10 Junction Block C11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1271 Junction Block C12 Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1272 8w-10-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1273 8w-10-3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1274 8w-10-4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1275 8w-10-5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1276 8w-10-6 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1277 8w-10-7 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1278 8w-10-8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1279 8w-10-9 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1280 8w-10-10 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1281 8w-10-11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1282 8w-10-12 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1283 Fuse Block: Electrical Diagrams 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1284 8w-12-3 Wiring Diagrams Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1285 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1286 8w-12-6 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1287 8w-12-7 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1288 8w-12-8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1289 8w-12-9 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1290 8w-12-10 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1291 8w-12-11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1292 8w-12-12 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1293 8w-12-13 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1294 8w-12-14 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1295 8w-12-15 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1296 8w-12-16 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1297 8w-12-17 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1298 8w-12-18 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1299 8w-12-19 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1300 8w-12-20 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1301 8w-12-21 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1302 8w-12-22 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams See: Diagrams/Electrical Diagrams Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 1303 Fuse Block: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Junction Block Fuse Block: Application and ID Junction Block Junction Block Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Junction Block > Page 1306 Fuse Block: Application and ID Power Distribution Center Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Page 1307 Fuse Block: Description and Operation Fig. 5 Junction Block Location An electrical Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover (Fig. 5). The JB serves to simplify and centralize numerous electrical components, and to distribute electrical current to many of the accessory systems in the vehicle. It also eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. The JB houses up to nineteen blade-type fuses (two standard-type and seventeen mini-type), up to two blade- type automatic resetting circuit breakers, and two International Standards Organization (ISO) relays (one standard-type and one micro-type). The molded plastic JB housing has integral mounting brackets that are secured with two screws to the left instrument panel end bracket. The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed for service of the JB. A fuse puller and spare fuse holders are located on the back of the fuse access cover, as well as an adhesive-backed fuse layout map to ensure proper fuse identification. The JB unit cannot be repaired and is only serviced as an assembly. If any internal circuit or the JB housing is faulty or damaged, the entire JB unit must be replaced. All of the circuits entering and leaving the JB do so through up to nine wire harness connectors, which are connected to the JB through integral connector receptacles molded into the JB housing. Internal connection of all of the JB circuits is accomplished by an intricate combination of hard wiring and bus bars. Refer to Junction Block for the location of complete JB circuit diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Page 1308 Fuse Block: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Fig. 6 Fuse Access Panel Remove/Install 2. Remove the fuse access panel by unsnapping it from the left outboard end of the instrument panel (Fig. 6). 3. Reach through the instrument panel fuse access panel opening to access and remove the one screw that secures the Junction Block (JB) to the left instrument panel end bracket. 4. Remove the steering column opening cover from the instrument panel. Refer to Steering Column Opening Cover for the location of the steering column opening cover removal procedures. Fig. 7 Junction Block Remove/Install 5. Reach through the outboard side of the instrument panel steering column opening to access and disconnect all of the wire harness connectors from the JB connector receptacles (Fig. 7). 6. Reach through the outboard side of the instrument panel steering column opening to access and remove the relay and fuse block from the JB. Push Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Page 1309 the relay and fuse block towards the left end of the instrument panel to disengage its mounting slots from the tabs on the JB. 7. Reach through the outboard side of the instrument panel steering column opening to access and remove the one screw that secures the JB to the left instrument panel end bracket. 8. Reach through the outboard side of the instrument panel steering column opening to remove the JB from the left instrument panel end bracket. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: If the Junction Block (JB) is being replaced with a new unit, be certain to transfer each of the fuses, circuit breakers and relays from the faulty JB to the proper cavities of the replacement JB. Refer to Junction Block for the location of complete circuit diagrams and cavity assignments for the JB. 1. Reach through the outboard side of the instrument panel steering column opening to position the JB onto the left instrument panel end bracket. 2. Reach through the outboard side of the instrument panel steering column opening to install and tighten the one screw that secures the JB to the left instrument panel end bracket. Tighten the screw to 2.2 Nm (20 in. lbs.). 3. Reach through the outboard side of the instrument panel steering column opening to access and install the relay and fuse block onto the JB by engaging the relay and fuse block mounting slots with the tabs on the JB. 4. Reach through the outboard side of the instrument panel steering column opening to access and reconnect all of the wire harness connectors to the JB connector receptacles. 5. Install the steering column opening cover onto the instrument panel. Refer to Steering Column Opening Cover for the location of the steering column opening cover installation procedures. 6. Reach through the instrument panel fuse access panel opening to install and tighten the one screw that secures the junction block to the left instrument panel end bracket. Tighten the screw to 2.2 Nm (20 in. lbs.). 7. Install the fuse access panel by snapping it onto the left outboard end of the instrument panel. 8. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Junction Block Relay Box: Locations Junction Block Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Junction Block > Page 1314 Relay Box: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block Relay Box: Diagrams Junction Block 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1317 8w-12-3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1318 8w-12-4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1319 8w-12-5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1320 Junction Block C1 Junction Block C2 Junction Block C3 Junction Block C4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1321 Junction Block C5 Junction Block C6 Junction Block C7 Junction Block C8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1322 Junction Block C9 Junction Block C10 Junction Block C11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1323 Junction Block C12 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1324 Relay Box: Diagrams Power Distribution Center 8w-10-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1325 8w-10-3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1326 8w-10-4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1327 8w-10-5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1328 8w-10-6 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1329 8w-10-7 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1330 8w-10-8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1331 8w-10-9 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1332 8w-10-10 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1333 8w-10-11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1334 8w-10-12 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Page 1335 Relay Box: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Junction Block Relay Box: Application and ID Junction Block Junction Block Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Junction Block > Page 1338 Relay Box: Application and ID Power Distribution Center Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Page 1339 Relay Box: Description and Operation Fig. 10 Relay And Fuse Block Location RELAY CENTER The relay and fuse block is snap fit onto mounting tabs located on the end of the Junction Block (JB) nearest to the dash panel, under the left outboard end of the instrument panel (Fig. 10). The relay and fuse block provides additional capacity for distribution and control of electrical current for some of the accessory systems that are unique to this vehicle, and which could not be accommodated by the JB or the Power Distribution Center (PDC). The relay and fuse block has cavities for up to four additional blade4ype mini fuses, the electronic combination flasher, and three additional International Standards Organization relays (one standard-type and two micro-type). The relay and fuse block components are accessed for service by removing the steering column opening cover from the instrument panel. The relay and fuse block is then disengaged from the JB mounting tabs and pulled out from under the instrument panel. Service replacement of the relay and fuse block unit requires instrument panel assembly removal. The relay and fuse block unit cannot be repaired and is only serviced as a unit with the instrument panel wire harness assembly. If the relay and fuse block housing or its internal circuits are faulty or damaged, the entire instrument panel wire harness unit must be replaced. The relay and fuse block is integral to the instrument panel wire harness, and all circuits entering or leaving this module do so through the instrument panel wire harness. Internal connection of all of the relay and fuse block circuits is accomplished by hard wiring. Refer to Fuse/Fuse Block for the location of complete circuit diagrams and cavity assignments for the relay and fuse block. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Page 1340 Relay Box: Service and Repair REMOVAL The relay and fuse block is serviced as a unit with the instrument panel wire harness. If any internal circuit of the relay and fuse block or the relay and fuse block housing is faulty or damaged, the entire instrument panel wire harness unit must be replaced. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel assembly from the dash panel. Refer to Instrument Panel Assembly for the instrument panel assembly removal procedures. 3. Disconnect each of the instrument panel wire harness connectors. Refer to Connector Locations for the location of more information on the instrument panel wire harness connector locations. 4. Remove all of the fasteners that secure each of the instrument panel wire harness ground eyelets to the instrument panel components. Refer to Connector Locations for the location of more information on the ground eyelet locations. 5. Disengage each of the retainers that secure the instrument panel wire harness to the instrument panel components. Refer to Connector Locations for the location of more information on the instrument panel wire harness retainer locations. Fig. 11 Relay And Fuse Block Remove/Install 6. Push the relay and fuse block towards the left end of the instrument panel to disengage its mounting slots from the tabs on the Junction Block (JB) (Fig. 11). 7. Remove the relay and fuse block and the instrument panel wire harness from the instrument panel as a unit. INSTALLATION The relay and fuse block is serviced as a unit with the instrument panel wire harness. If any internal circuit of the relay and fuse block or the relay and fuse block housing is faulty or damaged, the entire instrument panel wire harness unit must be replaced. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: If the relay and fuse block is being replaced with a new unit, be certain to transfer each of the fuses, the flasher and the relays from the faulty relay and fuse block to the proper cavities of the replacement relay and fuse block. Refer to Fuse' Fuse Block for the location of complete relay and fuse block circuit diagrams and cavity assignments. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Page 1341 1. Position the relay and fuse block and the instrument panel wire harness onto the instrument panel. 2. Install the relay and fuse block by engaging its mounting slots onto the tabs on the Junction Block (JB). 3. Engage each of the retainers that secure the instrument panel wire harness to the instrument panel components. Refer to Connector Locations for the location of more information on the instrument panel wire harness retainer locations. 4. Install all of the fasteners that secure each of the instrument panel wire harness ground eyelets to the instrument panel components. Refer to Connector Locations for the location of more information on the ground eyelet locations. 5. Reconnect each of the instrument panel wire harness connectors. Refer to Connector Locations for the location of more information on the instrument panel wire harness connector locations. 6. Install the instrument panel assembly onto the dash panel. Refer to Instrument Panel Assembly for the location of the instrument panel assembly installation procedures. 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Application and ID Maintenance Required Lamp/Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Maintenance Required ........................................................................................................................ ................................................................ PC194 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Locations Malfunction Indicator Lamp: Locations The MIL is located in the Information Center area of the instrument cluster overlay, to the left of center. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Locations > Page 1349 Malfunction Indicator Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Check Engine ...................................................................................................................................... ............................................................... PC194 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Locations > Page 1350 Malfunction Indicator Lamp: Description and Operation A Malfunction Indicator Lamp (MIL) is standard equipment on all instrument clusters. The MIL is located in the Information Center area of the instrument cluster overlay, to the left of center. The MIL consists of a stencilled cutout of the International Control and Display Symbol icon for "Engine" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber lens behind the cutout in the opaque layer of the overlay causes the icon to appear in amber through the translucent outer layer of the overlay when the indicator is illuminated from behind by a Light Emitting Diode (LED) soldered onto the instrument cluster electronic circuit board. The MIL is serviced as a unit with the instrument cluster. The Malfunction Indicator Lamp (MIL) gives an indication to the vehicle operator when the Powertrain Control Module (PCM) has recorded a Diagnostic Trouble Code (DTC) for an On-Board Diagnostics II (OBDII) emissions-related circuit or component malfunction. The MIL is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the PCM over the Programmable Communications Interface (PCI) data bus. The MIL Light Emitting Diode (LED) receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions; therefore, the LED will always be OFF when the ignition switch is in any position except ON or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the MIL for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the indicator is illuminated for about seven seconds as a bulb test. - PCM Lamp-ON Message - Each time the cluster receives a lamp-on message from the PCM, the indicator will be illuminated. The indicator can be flashed ON and OFF, or illuminated solid, as dictated by the PCM message. For some DTC's, if a problem does not recur, the PCM will send a lamp-off message automatically. Other DTC's may require that a fault be repaired and the PCM be reset before a lamp-OFF message will be sent. For more information on the PCM, and the DTC set and reset parameters, (Refer to EMISSIONS CONTROL - OPERATION). - Communication Error - If the cluster receives no lamp-on message from the PCM for twenty seconds, the MIL is illuminated by the instrument cluster to indicate a loss of bus communication. The indicator remains controlled and illuminated by the cluster until a valid lamp-ON message is received from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the indicator will be turned ON during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the fuel and emissions system circuits and sensors to decide whether the system is in good operating condition. The PCM then sends the proper lamp-ON or lamp-OFF messages to the instrument cluster. If the instrument cluster turns ON the MIL after the bulb test, it may indicate that a malfunction has occurred and that the fuel and emissions systems may require service. For proper diagnosis of the fuel and emissions systems, the PCM, the PCI data bus, or the message inputs to the instrument cluster that control the MIL, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation Oil Change Reminder Lamp: Description and Operation This Vehicle does not come equipped with an OIL CHANGE REMINDER LAMP. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation > Page 1354 Oil Change Reminder Lamp: Service and Repair This Vehicle does not come equipped with an OIL CHANGE REMINDER LAMP. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Description and Operation Spare Tire: Description and Operation DESCRIPTION - SPARE TIRE & TEMPORARY The temporary spare tire is designed for emergency use only. The original tire should be repaired or replaced at the first opportunity, then reinstalled. Do not exceed speeds of 50 M.P.H. when using the temporary spare tire. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Description and Operation > Page 1360 Spare Tire: Service and Repair SPARE TIRE WINCH REMOVAL 1. Remove spare tire. 2. Remove bolts attaching spare tire winch to crossmember. 3. Disengage clip attaching extension tube to spare tire winch. 4. Separate snare tire winch from vehicle. INSTALLATION 1. Position extension tube on spare tire winch and engage clip. 2. Position spare tire winch on vehicle. 3. Install bolts attaching spare tire winch to spare tire bracket. 4. Install spare tire. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation Wheels: Description and Operation DESCRIPTION The rim size is on the vehicle safety certification label located on the drivers door shut face. The size of the rim is determined by the drivetrain package. Original equipment wheels/rims are designed for operation up to the specified maximum vehicle capacity. Fig. 1 All models use stamped steel, cast aluminum or forged aluminum wheels. Every wheel has raised sections between the rim flanges and rim drop well called safety humps. Initial inflation of the tire forces the bead over these raised sections. In case of rapid loss of air pressure, the raised sections help hold the tire on the wheel. The wheel studs and nuts are designed for specific applications. All aluminum and some steel wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Do not use replacement studs or nuts with a different design or lesser quality. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation > Page 1364 Wheels: Testing and Inspection WHEEL REPLACEMENT Wheels must be replaced if they have: Excessive runout - Bent or dented - Leak air through welds - Have damaged bolt holes Wheel repairs employing hammering, heating, or welding are not allowed. Original equipment wheels are available through your dealer. Replacement wheels from any other source should be equivalent in: Load carrying capacity - Diameter - Width - Offset - Mounting configuration Failure to use equivalent replacement wheels may affect the safety and handling of your vehicle. Replacement with used wheels is not recommended. Their service history may have included severe treatment. WHEEL INSPECTION Inspect wheels for: Excessive run out - Dents or cracks - Damaged wheel lug nut holes - Air Leaks from any area or surface of the rim NOTE: Do not attempt to repair a wheel by hammering, heating or welding. If a wheel is damaged an original equipment replacement wheel should be used. When obtaining replacement wheels, they should be equivalent in load carrying capacity. The diameter, width, offset, pilot hole and bolt circle of the wheel should be the same as the original wheel. WARNING: FAILURE TO USE EQUIVALENT REPLACEMENT WHEELS MAY ADVERSELY AFFECT THE SAFETY AND HANDLING OF THE VEHICLE. USED WHEELS ARE NOT RECOMMENDED. THE SERVICE HISTORY OF THE WHEEL MAY HAVE INCLUDED SEVERE TREATMENT OR VERY HIGH MILEAGE. THE RIM COULD FAIL WITHOUT WARNING. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Mechanical Specifications Wheel Bearing: Mechanical Specifications Hub/Bearing Spindle Nut 185 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Mechanical Specifications > Page 1369 Wheel Bearing: Fluid Type Specifications Use Mopar Multi-Purpose Lubricant or equivalent. (labeled NGLI Grade 2 EP, GC-LB) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 1370 Wheel Bearing: Service and Repair REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove brake caliper, rotor, and ABS wheel speed sensor if equipped. 4. Remove hub/bearing spindle nut and discard nut. CAUTION: The hub/bearing spindle nut can not be re-used. INSTALLATION 1. Slide hub/bearing on spindle. 2. Install new spindle nut and tighten to 251 Nm (185 ft. lbs.). 3. Install brake rotor, caliper, and ABS wheel speed sensor if equipped. 4. Install wheel and tire assembly. 5. Remove support and lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Specifications Wheel Hub: Specifications Hub/Bearing Spindle Nut 185 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Specifications > Page 1374 Wheel Hub: Service and Repair REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove brake caliper, rotor, and ABS wheel speed sensor if equipped. 4. Remove hub/bearing spindle nut and discard nut. CAUTION: The hub/bearing spindle nut can not be re-used. INSTALLATION 1. Slide hub/bearing on spindle. 2. Install new spindle nut and tighten to 251 Nm (185 ft. lbs.). 3. Install brake rotor, caliper, and ABS wheel speed sensor if equipped. 4. Install wheel and tire assembly. 5. Remove support and lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Tightening Sequence Wheel Fastener: Specifications Tightening Sequence Wheel Torque Sequence - Master Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Tightening Sequence > Page 1379 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 1380 Wheel Fastener: Service and Repair STUDS REMOVAL - WHEEL STUDS 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper, caliper adapter and rotor. Fig. 9 4. Remove the stud from the hub with Remover C-4150A. INSTALLATION - WHEEL STUDS 1. Install the new stud into the hub flange. 2. Install the three washers onto stud, then install lug nut with the flat side of the nut against the washers. 3. Tighten the lug nut until the stud is pulled into the hub flange. Verify that the stud is properly seated into the flange. 4. Remove the lug nut and washers. 5. Install the brake rotor, caliper adapter, and caliper. 6. Install the wheel and tire assembly, use new lug nut on the stud or studs that were replaced. 7. Remove the support and lower the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications CYLINDER COMPRESSION PRESSURE RANGE: Compression Pressure ........................................................................................................................ ............................................................... 140 - 180 psi Maximum Allowable Variance Between Cylinders ....................................................................................................................................................... 25 % Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1386 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Secure the throttle in the wide-open position. 4. Disable the fuel system. 5. Remove the ASD relay. 6. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. 7. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders. 8. Refer to SPECIFICATIONS for the correct engine compression pressures. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications > Camshaft Bearing Bore Specifications Camshaft Bearing: Specifications Camshaft Bearing Bore Specifications Camshaft Bearing Journal Diameter .................................................................................................................................................... 1.0227 - 1.0235 inch Camshaft Bearing Clearance ............................................................................. ..................................................................................... 0.001 - 0.0026 inch Camshaft Bearing Clearance (Max.) ................................................................................................................................. ................................. 0.0026 inch Camshaft Bearing Cap Bolt ........................................................... ....................................................................................................................... 100 in. lbs Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications > Camshaft Bearing Bore Specifications > Page 1392 Camshaft Bearing: Specifications Camshaft Bearing Cap Torque & Sequence Camshaft Bearing Caps - Left Side Left Side Camshaft Camshaft Bearing Caps - Right Side Right Side Camshaft Tighten the bearing cap bolts in 1/2 turn increments following the sequence shown to 11 Nm (100 in. lbs.). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications > Camshaft Bearing Bore Specifications > Page 1393 Camshaft Bearing: Specifications Bearing Cap Bolts 100 inch lbs. working in 1/2 turn increments, tighten the bearing cap retaining bolts starting with the middle cap working outward. Bore Diameter 1.0245- 1.0252 inch Bearing Journal Diameter 1.0227 - 1.0235 inch Bearing Clearance 0.001 - 0.0026 inch Bearing Clearance 0.0026 inch End Play 0.003 - 0.0079 inch End Play (MAX) 0.0079 inch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Torque Torque Camshaft Non-Oiled Sprocket Bolt 90 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications Camshaft Bearing Journal Diameter 1.0227 - 1.0235 in Bearing Clearance 0.001 - 0.0026 in Bearing Clearance (MAX) 0.0026 in End Play 0.003 - 0.0079 in End Play (MAX) 0.0079 in Valve Timing Intake Opens 3.6 deg ATDC Intake Closes 247.1 deg ATDC Intake Duration 243.5 deg Exhaust Opens 232.5 deg BTDC Exhaust Closes 21.2 deg ATDC Exhaust Duration 253.70 deg Valve Overlap 17.6 deg Valve Lift (Zero Lash) Intake 0.443 in Exhaust 0.4292 in Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Description and Operation > Left Camshaft Camshaft: Description and Operation Left Camshaft DESCRIPTION The camshafts consist of powdered metal steel lobes which are sinter-bonded to a steel tube. A steel post or nose piece is friction-welded to the steel camshaft tube. Five bearing journals are machined into the camshaft, four on the steel tube and one on the steel nose piece. Camshaft end play is controlled by two thrust walls that border the nose piece journal. Engine oil enters the hollow camshafts at the third journal and lubricates every intake lobe rocker through a drilled passage in the intake lobe. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Description and Operation > Left Camshaft > Page 1402 Camshaft: Description and Operation Right Camshaft DESCRIPTION The camshafts consist of powdered metal steel lobes which are sinter-bonded to a steel tube. A steel post or nose piece is friction-welded to the steel camshaft tube. Five bearing journals are machined into the camshaft, four on the steel tube and one on the steel nose piece. Camshaft end play is controlled by two thrust walls that border the nose piece journal. Engine oil enters the hollow camshafts at the third journal and lubricates every intake lobe rocker through a drilled passage in the intake lobe. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Left Camshaft Camshaft: Service and Repair Left Camshaft REMOVAL CAUTION: When the timing chain is removed and the cylinder heads are still installed, DO NOT forcefully rotate the camshafts or crankshaft independently of each other. Severe valve and/or piston damage can occur. CAUTION: When removing the cam sprocket, timing chains or camshaft, Failure to use Special Tool 8350 will result in hydraulic tensioner ratchet over extension, requiring timing chain cover removal to reset the tensioner ratchet. 1. Remove cylinder head cover. 2. Set engine to TDC cylinder #1, camshaft sprocket V8 marks at the 12 o'clock position. 3. Mark one link on the secondary timing chain on both sides of the V8 mark on the camshaft sprocket to aid in installation. CAUTION: Do not hold or pry on the camshaft target wheel (Located on the right side camshaft sprocket) for any reason, Severe damage will occur to the target wheel resulting in a vehicle no start condition. 4. Loosen but DO NOT remove the camshaft sprocket retaining bolt. Leave the bolt snug against the sprocket. NOTE: The timing chain tensioners must be secured prior to removing the camshaft sprockets. Failure to secure tensioners will allow the tensioners to extend, requiring timing chain cover removal in order to reset tensioners. CAUTION: Do not force wedge past the narrowest point between the chain strands. Damage to the tensioners may occur. 5. Position Special Tool 8350 timing chain wedge between the timing chain strands, tap the tool to securely wedge the timing chain against the tensioner arm and guide (Fig. 28). NOTE: When gripping the camshaft, place the pliers on the tube portion of the camshaft only. Do not grip the lobes or the sprocket areas. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Left Camshaft > Page 1405 6. Hold the camshaft with adjustable pliers while removing the camshaft sprocket bolt and sprocket (Fig. 29). 7. Using the pliers, gently allow the camshaft to rotate 15° clockwise until the camshaft is in the neutral position (no valve load). 8. Starting at the outside working inward, loosen the camshaft bearing cap retaining bolts 1/2 turn at a time. Repeat until all load is off the bearing caps. CAUTION: DO NOT STAMP OR STRIKE THE CAMSHAFT BEARING CAPS. SEVERE DAMAGE WILL OCCUR TO THE BEARING CAPS. NOTE: When the camshaft is removed the rocker arms may slide downward, mark the rocker arms before removing camshaft. 9. Remove the camshaft bearing caps and the camshaft. INSTALLATION 1. Lubricate camshaft journals with clean engine oil. NOTE: Position the left side camshaft so that the camshaft sprocket dowel is near the 1 o'clock position, This will place the camshaft at the neutral position easing the installation of the camshaft bearing caps. 2. Position the camshaft into the cylinder head. 3. Install the camshaft bearing caps, hand tighten the retaining bolts. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Left Camshaft > Page 1406 4. Working in 1/2 turn increments, tighten the bearing cap retaining bolts starting with the middle cap working outward (Fig. 30). 5. Torque the camshaft bearing cap retaining bolts to 11 Nm (100 in. lbs.). 6. Position the camshaft drive gear into the timing chain aligning the V8 mark between the two marked chain links (Two links marked during removal) (Fig. 31). NOTE: When gripping the camshaft, place the pliers on the tube portion of the camshaft only. Do not grip the lobes or the sprocket areas. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Left Camshaft > Page 1407 7. Using the adjustable pliers, rotate the camshaft until the camshaft sprocket dowel is aligned with the slot in the camshaft sprocket. Install the sprocket onto the camshaft (Fig. 32). CAUTION: Remove excess oil from camshaft sprocket bolt. Failure to do so can cause bolt overtorque resulting in bolt failure. 8. Remove excess oil from bolt, then install the camshaft sprocket retaining bolt and hand tighten. 9. Remove Special Tool 8350 timing chain wedge (Fig. 33). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Left Camshaft > Page 1408 10. Using Special Tool 6958 spanner wrench with adapter pins 8346 (Fig. 34), torque the camshaft sprocket retaining bolt to 122 Nm (90 ft. lbs.). 11. Install the cylinder head cover. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Left Camshaft > Page 1409 Camshaft: Service and Repair Right Camshaft REMOVAL CAUTION: When the timing chain is removed and the cylinder heads are still installed, DO NOT forcefully rotate the camshafts or crankshaft independently of each other. Severe valve and/or piston damage can occur. CAUTION: When removing the cam sprocket, timing chains or camshaft, Failure to use special tool 8350 will result in hydraulic tensioner ratchet over extension, Requiring timing chain cover removal to re-set the tensioner ratchet. 1. Remove the cylinder head covers. 2. Set engine to TDC cylinder #1, camshaft sprocket V8 marks at the 12 o'clock position. 3. Mark one link on the secondary timing chain on both sides of the V8 mark on the camshaft sprocket to aid in installation. CAUTION: Do not hold or pry on the camshaft target wheel for any reason, Severe damage will occur to the target wheel. A damaged target wheel could cause a vehicle no start condition. 4. Loosen but DO NOT remove the camshaft sprocket retaining bolt. Leave bolt snug against sprocket. NOTE: The timing chain tensioners must be secured prior to removing the camshaft sprockets. Failure to secure tensioner will allow the tensioners to extend, requiring timing chain cover removal in order to reset tensioners. CAUTION: Do not force wedge past the narrowest point between the chain strands. Damage to the tensioners may occur. 5. Position Special Tool 8350 timing chain wedge between the timing chain strands. Tap the tool to securely wedge the timing chain against the tensioner arm and guide (Fig. 35). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Left Camshaft > Page 1410 6. Remove the camshaft position sensor (Fig. 36). NOTE: When gripping the camshaft, place the pliers on the tube portion of the camshaft only. Do not grip the lobes or the sprocket areas. 7. Hold the camshaft with adjustable pliers while removing the camshaft sprocket bolt and sprocket (Fig. 37). 8. Using the pliers, gently allow the camshaft to rotate 45° counter-clockwise until the camshaft is in the neutral position (no valve load). 9. Starting at the outside working inward, loosen the camshaft bearing cap retaining bolts 1/2 turn at a time. Repeat until all load is off the bearing caps. CAUTION: DO NOT STAMP OR STRIKE THE CAMSHAFT BEARING CAPS. SEVERE DAMAGE WILL OCCUR TO THE BEARING CAPS. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Left Camshaft > Page 1411 NOTE: When the camshaft is removed the rocker arms may slide downward, mark the rocker arms before removing camshaft. 10. Remove the camshaft bearing caps and the camshaft. INSTALLATION 1. Lubricate camshaft journals with clean engine oil. NOTE: Position the right side camshaft so that the camshaft sprocket dowel is near the 10 o'clock position, This will place the camshaft at the neutral position easing the installation of the camshaft bearing caps. 2. Position the camshaft into the cylinder head. 3. Install the camshaft bearing caps, hand tighten the retaining bolts. 4. Working in 1/2 turn increments, tighten the bearing cap retaining bolts starting with the middle cap working outward (Fig. 38). 5. Torque the camshaft bearing cap retaining bolts to 11 Nm (100 in. lbs.). 6. Position the camshaft drive gear into the timing chain aligning the V8 mark between the two marked chain links (Two links marked during Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Left Camshaft > Page 1412 removal) (Fig. 39). NOTE: When gripping the camshaft, place the pliers on the tube portion of the camshaft only. Do not grip the lobes or the sprocket areas. 7. Using the adjustable pliers, rotate the camshaft until the camshaft sprocket dowel is aligned with the slot in the camshaft sprocket. Install the sprocket onto the camshaft (Fig. 40). CAUTION: Remove excess oil from camshaft sprocket bolt. Failure to do so can cause bolt overtorque resulting in bolt failure. 8. Remove excess oil from camshaft sprocket bolt, then install the camshaft sprocket retaining bolt and hand tighten. 9. Remove timing chain wedge special tool 8350 (Fig. 35). 10. Using Special Tool 6958 spanner wrench with adapter pins 8346 (Fig. 41), torque the camshaft sprocket retaining bolt to 122 Nm (90 ft. lbs.). 11. Install the camshaft position sensor (Fig. 36). 12. Install the cylinder head cover. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Description and Operation Rocker Arm Assembly: Description and Operation DESCRIPTION The rocker arms are steel stampings with an integral roller bearing. The rocker arms incorporate a 2.8 mm (0.11 inch) oil hole in the lash adjuster socket for roller and camshaft lubrication. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Description and Operation > Page 1416 Rocker Arm Assembly: Testing and Inspection DIAGNOSIS AND TESTING-HYDRAULIC LASH ADJUSTER A tappet-like noise may be produced from several items. Check the following items. 1. Engine oil level too high or too low. This may cause aerated oil to enter the adjusters and cause them to be spongy. 2. Insufficient running time after rebuilding cylinder head. Low speed running up to I hour may be required. 3. Turn engine off and let set for a few minutes before restarting. Repeat this several times after engine has reached normal operating temperature. 4. Low oil pressure. 5. The oil restrictor in cylinder head gasket or the oil passage to the cylinder head is plugged with debris. 6. Air ingested into oil due to broken or cracked oil pump pick up. 7. Worn valve guides. 8. Rocker arm ears contacting valve spring retainer. 9. Rocker arm loose, adjuster stuck or at maximum extension and still leaves lash in the system. 10. Oil leak or excessive cam bore wear in cylinder head. 11. Faulty lash adjuster. - Check lash adjusters for sponginess while installed in cylinder head and cam on camshaft at base circle. Depress part of rocker arm over adjuster. Normal adjusters should feel very firm. Spongy adjusters can be bottomed out easily. - Remove suspected lash adjusters, and replace. - Before installation, make sure adjusters are at least partially full of oil. This can be verified by little or no plunger travel when lash adjuster is depressed. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Description and Operation > Page 1417 Rocker Arm Assembly: Service and Repair REMOVAL NOTE: Disconnect the battery negative cable to prevent accidental starter engagement. 1. Remove the cylinder head cover. 2. For rocker arm removal on cylinders 3 and 5 Rotate the crankshaft until cylinder # 1 is at TDC exhaust stroke. 3. For rocker arm removal on cylinders 2 and 8 Rotate the crankshaft until cylinder # 1 is at TDC compression stroke. 4. For rocker arm removal on cylinders 4 and 6 Rotate the crankshaft until cylinder # 3 is at TDC compression stroke. 5. For rocker arm removal on cylinders 1 and 7 Rotate the crankshaft until cylinder # 2 is at TDC compression stroke. 6. Using special tool 8516 Rocker Arm Remover, press downward on the valve spring, remove rocker arm (Fig. 45). INSTALLATION CAUTION: Make sure the rocker arms are installed with the concave pocket over the lash adjusters. Failure to do so may cause severe damage to the rocker arms and/or lash adjusters. NOTE: Coat the rocker arms with clean engine oil prior to installation. 1. For rocker arm installation on cylinders 3 and 5 Rotate the crankshaft until cylinder # 1 is at TDC exhaust stroke. 2. For rocker arm installation on cylinders 2 and 8 Rotate the crankshaft until cylinder # 1 is at TDC compression stroke. 3. For rocker arm installation on cylinders 4 and 6 Rotate the crankshaft until cylinder # 3 is at TDC compression stroke. 4. For rocker arm installation on cylinders 1 and 7 Rotate the crankshaft until cylinder # 2 is at TDC compression stroke. 5. Using special tool 8516 press downward on the valve spring, install rocker arm (Fig. 45). 6. Install the cylinder head cover. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Bearing Clearance 0.0004 - 0.0019 inch Piston Pin Bore Diameter (Interference Fit) 0.0009 - 0.0018 inch Bearing Bore Out of Round (MAX) 0.0002 inch Total Weight Bearing 19.5771 Ounces Connecting Rod Cap-Bolts 20 ft. lbs. PLUS 90°TURN Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 1422 Connecting Rod Bearing: Service and Repair STANDARD PROCEDURE-CONNECTING ROD BEARING FITTING Inspect the connecting rod bearings for scoring and bent alignment tabs (Fig. 50) (Fig. 51). Check the bearings for normal wear patterns, scoring, grooving, fatigue and pitting (Fig. 52). Replace any bearing that shows abnormal wear. Inspect the connecting rod journals for signs of scoring, nicks and burrs. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 1423 Misaligned or bent connecting rods can cause abnormal wear on pistons, piston rings, cylinder walls, connecting rod bearings and crankshaft connecting rod journals. If wear patterns or damage to any of these components indicate the probability of a misaligned connecting rod, inspect it for correct rod alignment. Replace misaligned, bent or twisted connecting rods. 1. Wipe the oil from the connecting rod journal. 2. Lubricate the upper bearing insert and install in connecting rod. 3. Use piston ring compressor and Guide Pins Special Tool 8507 (Fig. 53) to install the rod and piston assemblies. The oil slinger slots in the rods must face front of the engine. The "F"s near the piston wrist pin bore should point to the front of the engine. 4. Install the lower bearing insert in the bearing cap. The lower insert must be dry. Place strip of Plastigage across full width of the lower insert at the center of bearing cap. Plastigage must not crumble in use. If brittle, obtain fresh stock. 5. Install bearing cap and connecting rod on the journal and tighten bolts to 27 Nm (20 ft. lbs.) plus a 90° turn. DO NOT rotate crankshaft. Plastigage will smear, resulting in inaccurate indication. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 1424 6. Remove the bearing cap and determine amount of bearing-to-journal clearance by measuring the width of compressed Plastigage (Fig. 54). Refer to Specifications for the proper clearance. Plastigage should indicate the same clearance across the entire width of the insert. If the clearance varies, it may be caused by either a tapered journal, bent connecting rod or foreign material trapped between the insert and cap or rod. 7. If the correct clearance is indicated, replacement of the bearing inserts is not necessary. Remove the Plastigage from crankshaft journal and bearing insert. Proceed with installation. 8. If bearing-to-journal clearance exceeds the specification, determine which services bearing set to use the bearing sizes are as follows: 9. Repeat the Plastigage measurement to verify your bearing selection prior to final assembly. 10. Once you have selected the proper insert, install the insert and cap. Tighten the connecting rod bolts to 27 Nm (20 ft. lbs.) plus a 90° turn. Slide snug-fitting feeler gauge between the connecting rod and crankshaft journal flange (Fig. 55). Refer to Specifications for the proper clearance. Replace the connecting rod if the side clearance is not within specification. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Connecting Rod: Specifications Bearing Clearance 0.0004 - 0.0019 in Side Clearance 0.004 - 0.0138 in Piston Pin Bore Diameter (Interference Fit) 0.0009 - 0.0018 inch Bearing Bore Out of Round (MAX) 0.0002 inch Total Weight (Less Bearing) 19.5771 oz (US) Connecting Rod Cap Bolts 1st step 20 ft.lb 2nd Step Plus 90 deg. Turn Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod > Page 1429 Connecting Rod: Specifications Connecting Rod Bolt/Nut Connecting Rod Cap Bolts ..................................................................................................................................................... 27 Nm (20 ft. lbs.) + 1/4 turn Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1430 Connecting Rod: Description and Operation For further information regarding this component please refer to Piston, Engine. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1431 Connecting Rod: Service and Repair For further information regarding this component please refer to Piston, Engine. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Specifications Crankshaft Gear/Sprocket: Specifications Crankshaft Damper Bolt 130 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Service Specifications Crankshaft Main Bearing: Specifications Main Bearing Journal Diameter Minimum 2.4996 in Maximum 2.5005 in Bearing Clearance Minimum 0.0008 in Maximum 0.0021 in Out of Round Maximum 0.0002 in Taper Maximum 0.0004 in Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Service Specifications > Page 1439 Crankshaft Main Bearing: Specifications Torque Specifications Install the bedplate retaining bolts, making sure to place the stud bolts in the correct location. Torque the bolts in the sequence shown. Tighten bolts A - L to 54 Nm (40 ft. lbs.). - Tighten bolts 1 - 10 to 2.8 Nm (25 in. lbs.). - Turn bolts 1 - 10 an additional 90 °. - Tighten bolts A1- A6 to 27 Nm (20 ft. lbs.). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 1440 Crankshaft Main Bearing: Service and Repair STANDARD PROCEDURE-CRANKSHAFT MAIN BEARING - FITTING MAIN BEARING JOURNAL DIAMETER (CRANKSHAFT REMOVED) Crankshaft removed from the cylinder block. Clean the oil off the main bearing journal. Determine the maximum diameter of the journal with a micrometer. Measure at two locations 90° apart at each end of the journal. The maximum allowable taper is 0.008 mm (0.0004 inch.) and maximum out of round is 0.005mm (0.002 inch). Compare the measured diameter with the journal diameter specification (Main Bearing Fitting Chart). Select inserts required to obtain the specified bearing-to-journal clearance. CRANKSHAFT MAIN BEARING SELECTION The main bearings are "select fit" to achieve proper oil clearances. For main bearing selection, the crankshaft position sensor target wheel has grade identification marks stamped into it (Fig. 63). These marks are read from left to right, corresponding with journal number 1, 2, 3, 4 and 5. The crankshaft position sensor target wheel is mounted to the number 8 counter weight on the crankshaft. NOTE: Service main bearings are coded. These codes identify what size (grade) the bearing is. MAIN BEARING SELECTION CHART-4.7L INSPECTION Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 1441 Wipe the inserts clean and inspect for abnormal wear patterns and for metal or other foreign material imbedded in the lining. Normal main bearing insert wear patterns are illustrated (Fig. 64). NOTE: If any of the crankshaft journals are scored, the crankshaft must be repaired or replaced. Inspect the back of the inserts for fractures, scrapings or irregular wear patterns. Inspect the upper insert locking tabs for damage. Replace all damaged or worn bearing inserts. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Main Bearing Journal Diameter 2.4996 - 2.5005 inch Bearing Clearance 0.0008 - 0.0021 inch Out of Round (MAX) 0.0002 inch Taper (Max) 0.0004 inch End Play 0.0021 - 0.0112 inch End Play (MAX) 0.0112 inch Connecting Rod Journal Diameter 2.0076 - 2.0082 inch Bearing Clearance 0.0006-0.0022 inch Out of Round (MAX) 0.0002 inch Taper (MAX) 0.0004 inch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1445 Crankshaft: Description and Operation DESCRIPTION The crankshaft is constructed of nodular cast iron. The crankshaft is a cross shaped four throw design with eight counterweights for balancing purposes. The crankshaft is supported by five select fit main bearings with the number three serving as the thrust washer location. The main journals of the crankshaft are cross drilled to improve rod bearing lubrication. The number eight counterweight has provisions for crankshaft position sensor target wheel mounting. The select fit main bearing markings are located on the rear side of the target wheel. The crankshaft oil seals are one piece design. The front oil seal is retained in the timing chain cover, and the rear seal is pressed in to a bore formed by the cylinder block and the bedplate assembly. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1446 Crankshaft: Service and Repair REMOVAL NOTE: To remove the crankshaft from the engine, the engine must be removed from the vehicle. 1. Remove the engine. 2. Remove the engine oil pump. CAUTION: DO NOT pry on the oil pan gasket when removing the oil pan, The oil pan gasket is mounted to the cylinder block in three locations and will remain attached to block when removing oil pan. Gasket can not be removed with oil pan. 3. Remove oil pan. 4. Remove the oil pump pickup tube and oil pan gasket /windage tray. 5. Remove the bedplate mounting bolts. Note the location of the three stud bolts for installation. 6. Remove the connecting rods from the crankshaft. CAUTION: The bedplate to cylinder block mating surface is a critical sealing surface. Do not pry on or damage this surface in anyway. NOTE: The bedplate contains the lower main bearing halves. Use care when handling bedplate as not to drop or damage bearing halves. Installing main bearing halves in the wrong position will cause sever damage to the crankshaft. NOTE: The bedplate has pry points cast into it. Use these points only. The pry points are on both the left and right sides, only the left side is shown. 7. Carefully pry on the pry points (Fig. 57) to loosen the bedplate then remove the bedplate. CAUTION: When removing the crankshaft, use care not to damage bearing surfaces on the crankshaft. 8. Remove the crankshaft. 9. Remove the crankshaft target wheel. INSPECTION NOTE: Thoroughly inspect the connecting rod bearing bores and main bearing bores for scoring, blueing or severe scratches. Further disassembly may be required. If connecting rod bearing bores show damage, the cylinder heads must be removed to service the piston and rod assemblies. If the bedplate or the Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1447 cylinder block main bearing bores show damage the engine must be replaced. 1. If required, remove the main bearing halves from the cylinder block and bedplate. 2. Thoroughly clean the bedplate to cylinder block sealing surfaces and main bearing bores. Remove all oil and sealant residue. 3. Inspect the bedplate main bearing bores for cracks, scoring or severe blueing. If either condition exists the engine must be replaced. 4. Inspect the crankshaft thrust washer for scoring, scratches or blueing. If either condition exist replace the thrust washer. 5. Inspect the oil pan gasket/windage tray for splits, tears or cracks in the gasket sealing surfaces. Replace gasket as necessary. INSTALLATION CAUTION: Main bearings are select fit. Refer to proper bearing selections. 1. Lubricate upper main bearing halves with clean engine oil. CAUTION: When installing crankshaft, use care not to damage bearing surfaces on the crankshaft. NOTE: Apply sealant to the target wheel retaining screws prior to installation. 2. Install the crankshaft target wheel. Torque the mounting screws to 22 Nm (21 ft. lbs.). 3. Position crankshaft in cylinder block. 4. Install the thrust washers (Fig. 58). CAUTION: The bedplate to cylinder block mateing surface must be coated with sealant prior to installation. Failure to do so will cause severe oil leaks. NOTE: The installation time to install the bedplate after the sealant has been applied is critical. NOTE: Make sure that the bedplate and cylinder block sealing surfaces are clean and free of oil or other contaminants. Contaminants on the sealing surfaces may cause main bearing distortion and/or oil leaks. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1448 5. Apply a 2.5 mm (0.100 inch) (Fig. 59) bead of Mopar, Gen. II Silicone Rubber Adhesive sealant to the cylinder block-to-bedplate mating surface as shown (Fig. 60). 6. Coat the crankshaft main bearing journals with clean engine oil and position the bedplate onto the cylinder block. NOTE: Lubricate the bedplate retaining bolts with clean engine oil prior to installation. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1449 7. Install the bedplate retaining bolts, making sure to place the stud bolts in the correct location, Torque the bolts in the sequence shown (Fig. 61). - Tighten bolts A - L to 54 Nm (40 ft. lbs.) - Tighten bolts 1-10 to 2.8 Nm (25 in. lbs.) - Turn bolts 1-10 an additional 90°. - Tighten bolts Al- A6 to 27 Nm (20 ft. lbs.) 8. Measure crankshaft end play. 9. Install the connecting rods and measure side clearance. 10. Position the oil pan gasket/windage tray, using a new O-ring, install the oil pickup tube. Torque the bolt to 28 Nm (20 ft. lbs.) torque the nuts to 28 Nm (20 ft. lbs.). 11. Install the oil pan. Torque the retaining bolts to 15 Nm (11 ft. lbs.) in the sequence shown (Fig. 62). 12. Install the engine. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation Engine Block Heater: Description and Operation DESCRIPTION WARNING: DO NOT OPERATE ENGINE UNLESS BLOCK HEATER CORD HAS BEEN DISCONNECTED FROM POWER SOURCE AND SECURED IN PLACE. THE POWER CORD MUST BE SECURED IN ITS RETAINING CLIPS AND ROUTED AWAY FROM EXHAUST MANIFOLDS AND MOVING PARTS. An optional engine block heater (Fig. 4) is available with all models. The heater is equipped with a power cord. The cord is attached to an engine compartment component with tie-straps. The heater warms the engine providing easier engine starting and faster warm-up in low temperatures. The heater is mounted in a core hole of the engine cylinder block in place of a freeze plug with the heating element immersed in engine coolant. OPERATION Connecting the power cord to a grounded 110-120 volt AC electrical outlet with a grounded, three wire extension cord activates the heating element warming the engine coolant. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Page 1453 Engine Block Heater: Testing and Inspection DIAGNOSIS AND TESTING-ENGINE BLOCK HEATER If the unit does not operate (Fig. 5), possible causes can be either the power cord or the heater element. Test the power cord for continuity with a 110-volt voltmeter or 110-volt test light. Test heater element continuity with an ohmmeter or a 12-volt test light. CAUTION: To prevent damage, the power cord must be secured in it's retainer clips and away from any components that may cause abrasion or damage, such as linkages, exhaust components, etc. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Page 1454 Engine Block Heater: Service and Repair REMOVAL 1. Disconnect negative battery cable from battery. 2. Drain coolant from radiator. 3. Raise vehicle. 4. Remove engine cylinder block drain plug(s) located on the sides of cylinder block above the oil pan rail (Fig. 6). 5. Remove power cord from block heater. 6. Loosen screw at center of block heater. Remove heater assembly (Fig. 7). INSTALLATION 1. Thoroughly clean cylinder block core hole and block heater seat. 2. Insert block heater assembly with element loop pointing at twelve o'clock (Fig. 7). 3. With block heater fully seated, tighten center screw to 2 Nm (17 in. lbs.) torque. 4. Refill cooling system. 5. Start and warm the engine. Check for leaks. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Expansion/Freeze Plug > Component Information > Service and Repair Expansion/Freeze Plug: Service and Repair CORE PLUGS REMOVAL 1. Drain the cooling system. 2. Using a blunt tool such as a drift or a screw driver and a hammer, strike the bottom edge of the cup plug (Fig. 56) 3. Using a suitable pair of pliers, grasp the core plug and remove. INSTALLATION NOTE: Thoroughly clean core plug bore, remove all of the old sealer. 1. Coat the edges of the engine core plug and the core plug bore with Mopar Gasket Maker, or equivalent. NOTE: It is not necessary to wait for the sealant to cure on the core plugs. The cooling system can be filled and the vehicle returned to service immediately. 2. Using proper plug driver, drive core plug into the core plug bore. The sharp edge of the core plug should be at least 0.50 mm (0.020 inch) inside the lead in chamfer. 3. Refill the cooling system. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Torque Torque Crankshaft Damper Bolt 130 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1461 Harmonic Balancer - Crankshaft Pulley: Service and Repair REMOVAL 1. Disconnect negative cable from battery. 2. Remove accessory drive belt. 3. Drain cooling system. 4. Remove radiator upper hose. 5. Remove upper fan shroud. 6. Using Special Tools 6958 Spanner with Adapter Pins 8346, loosen fan and viscous assembly from water pump (Fig. 82). 7. Remove fan and viscous assembly. 8. Disconnect electrical connector for fan mounted inside radiator shroud. NOTE: Transmission cooler line snaps into shroud lower right hand corner. 9. Remove crankshaft damper bolt. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1462 10. Remove damper using Special Tools 8513 Insert and 1026 Three Jaw Puller (Fig. 83). INSTALLATION CAUTION: To prevent severe damage to the Crankshaft, Damper or Special Tool 8512-A, thoroughly clean the damper bore and the crankshaft nose before installing Damper. 1. Align crankshaft damper slot with key in crankshaft. Slide damper onto crankshaft slightly. CAUTION: Special Tool 8512-A, is assembled in a specific sequence. Failure to assemble this tool in this sequence can result in tool failure and severe damage to either the tool or the crankshaft. 2. Assemble Special Tool 8512-A as follows, The nut is threaded onto the shaft first. Then the roller bearing is placed onto the threaded rod (The hardened bearing surface of the bearing MUST face the nut). Then the hardened washer slides onto the threaded rod (Fig. 84). Once assembled coat the threaded rod's threads with Mopar Nickel AntiSeize or (Loctite No. 771). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1463 3. Using Special Tool 8512-A, press damper onto crankshaft (Fig. 85). 4. Install then tighten crankshaft damper bolt to 175 Nm (130 ft. lbs.). 5. Install fan blade assembly. 6. Install radiator upper shroud and tighten fasteners to 11 Nm (95 in. lbs.). 7. Connect electrical connector for shroud fan. 8. Install radiator upper hose. 9. Install accessory drive belt. 10. Refill cooling system. 11. Connect negative cable to battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Material Aluminum Alloy Diameter 3.6605 inch Weight 12.96 oz Ring Groove Diameter No. 1 3.296 - 3.269 inch No. 2 3.261 - 3.310 inch No. 3 3.302 - 3.310 inch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1467 Piston: Description and Operation DESCRIPTION CAUTION: Do not use a metal stamp to mark connecting rods as damage may result, instead use ink or a scratch awl. The pistons are made of a high strength aluminum alloy. The anodized top ring groove and crown has been replaced with a coated top ring that is blue in color. Piston skirts are coated with a solid lubricant (Molykote) to reduce friction and provide scuff resistance. The connecting rods are made of forged powdered metal, with a "fractured cap" design. A pressed fit piston pin is used to attach the piston and connecting rod. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures Piston: Procedures Cleaning and Inspection CLEANING CAUTION: DO NOT use a wire wheel or other abrasive cleaning devise to clean the pistons or connecting rods. The pistons have a Moly coating, this coating must not be damaged. 1. Using a suitable cleaning solvent clean the pistons in warm water and towel dry. 2. Use a wood or plastic scraper to clean the ring land grooves. CAUTION: DO NOT remove the piston pin from the piston and connecting rod assembly. INSPECTION Check the connecting rod journal for excessive wear, taper and scoring. 4. Mark connecting rod and bearing cap positions using a permanent ink marker or scribe tool (Fig. 74) Check the connecting rod for signs of twist or bending. Check the piston for taper and elliptical shape before it is fitted into the cylinder bore. Check the piston for scoring, or scraping marks in the piston skirts. Check the ring lands for cracks and/or deterioration. Piston to Cylinder Bore Fitting STANDARD PROCEDURE-PISTON FITTING 1. To correctly select the proper size piston, a cylinder bore gauge, capable of reading in 0.003 mm. (0.0001 inch) INCREMENTS is required. If a bore gauge is not available, do not use an inside micrometer. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1470 2. Measure the inside diameter of the cylinder bore at a point 38.0 mm (1.5 inches) below top of bore. Start perpendicular (across or at 90 degrees) to the axis of the crankshaft at point A and then take an additional bore reading 90 degrees to that at point B (Fig. 73). 3. The coated pistons will be serviced with the piston pin and connecting rod pre-assembled. 4. The coating material is applied to the piston after the final piston machining process. Measuring the outside diameter of a coated piston will not provide accurate results (Fig. 72). Therefore measuring the inside diameter of the cylinder bore with a dial Bore Gauge is MANDATORY. To correctly select the proper size piston, a cylinder bore gauge capable of reading in 0.003 mm (0.0001 inch) increments is required. 5. Piston installation into the cylinder bore requires slightly more pressure than that required for non-coated pistons. The bonded coating on the piston will give the appearance of a line-to-line fit with the cylinder bore. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1471 Piston: Removal and Replacement REMOVAL 1. Disconnect negative cable from battery. 2. Remove the following components: - Oil pan and gasket/windage tray. - Cylinder head covers. - Timing chain cover. - Cylinder head(s). 3. If necessary, remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies from the engine, rotate crankshaft so the each connecting rod is centered in cylinder bore. CAUTION: DO NOT use a number stamp or a punch to mark connecting rods or caps, as damage to connecting rods could occur NOTE: Connecting rods and bearing caps are not interchangeable and should be marked before removing to ensure correct reassembly. CAUTION: Care must be taken not to damage the fractured rod and cap joint face surfaces, as engine damage may occur. 5. Remove connecting rod cap. Install Special Tool 8507 Connecting Rod Guides into the connecting rod being removed. Remove piston from cylinder bore. Repeat this procedure for each piston being removed. CAUTION: Care must be taken not to nick crankshaft journals, as engine damage may occur 6. Immediately after piston and connecting rod removal, install bearing cap on the mating connecting rod to prevent damage to the fractured cap and rod surfaces. 7. Carefully remove piston rings from piston(s), starting from the top ring down. INSTALLATION 1. Before installing piston and connecting rod assemblies into the bore, install the piston rings. 2. Immerse the piston head and rings in clean engine oil. Position a ring compressor over the piston and rings. Tighten ring compressor. Ensure position of rings do not change during this operation. 3. Position bearing onto connecting rod. Ensure that hole in bearing shell aligns with hole in connecting rod. Lubricate bearing surface with clean engine oil. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1472 4. Install Special Tool 8507 Connecting Rod Guides into connecting rod bolt threads (Fig. 75). 5. The pistons are marked on the piston pin bore surface with an raised "F" indicating installation position. This mark must be pointing toward the front of engine on both cylinder banks. The connecting rod oil slinger slot faces the front of the engine (Fig. 76). 6. Wipe cylinder bore clean and lubricate with engine oil. 7. Rotate crankshaft until connecting rod journal is on the center of cylinder bore. Insert rod and piston into cylinder bore and carefully position connecting rod guides over crankshaft journal. 8. Tap piston down in cylinder bore using a hammer handle. While at the same time, guide connecting rod into position on rod journal. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1473 CAUTION: Connecting Rod Bolts are Torque to Yield Bolts and Must Not Be Reused. Always replace the Rod Bolts whenever they are loosened or removed. 9. Lubricate rod bolts and bearing surfaces with engine oil. Install connecting rod cap and bearing. Tighten bolts to 27 Nm (20 ft. lbs.) plus 90°. 10. Install the following components: - Cylinder head(s). - Timing chain and cover. - Cylinder head covers. - Oil pan and gasket/windage tray. 11. Fill crankcase with proper engine oil to correct level. 12. Connect negative cable to battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Ring Gap Top Compression Ring 0.0146- 0.0249 inch Second Compression Ring 0.0146- 0.0249 inch Oil Control (Steel Rails) 0.0099- 0.30 inch Side Clearance Top Compression Ring 0.0020 - 0.0037 inch Second Compression Ring 0.0016 - 0.0031 inch Oil Ring (Steel Ring) 0.0007 - 0.0091 inch Ring Width Top Compression Ring 0.057 - 0.058 inch Second Compression Ring 0.057 - 0.058 inch Oil Ring (Steel Rails) 0.017 - 0.018 inch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1477 Piston Ring: Service and Repair STANDARD PROCEDURE-PISTON RING FITTING Before reinstalling used rings or installing new rings, the ring clearances must be checked. 1. Wipe the cylinder bore clean. 2. Insert the ring in the cylinder bore. NOTE: The ring gap measurement must be made with the ring positioned at least 12 mm (0.50 inch.) from bottom of cylinder bore. 3. Using a piston, to ensure that the ring is squared in the cylinder bore, slide the ring downward into the cylinder. 4. Using a feeler gauge check the ring end gap (Fig. 77). Replace any rings not within specification. PISTON RING SIDE CLEARANCE NOTE: Make sure the piston ring grooves are clean and free of nicks and burrs. 5. Measure the ring side clearance as shown (Fig. 78) make sure the feeler gauge fits snugly between the ring land and the ring. Replace any ring not within specification. 6. Rotate the ring around the piston, the ring must rotate in the groove with out binding. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1478 PISTON RING SPECIFICATION CHART Upper Ring 0.051 - 0.094 mm (0.0020- .0037 inch) 0.11 mm (0.004 inch) Intermediate Ring 0.04 0.08 mm (0.0016-0.0031 inch) 0.10 mm (0.004 inch) Oil Control Ring (Steel Rails) 0.019- 0.229mm (0.0007-.0090 inch) 0.25mm (0.010 inch) Ring Position Ring Gap Wear Limit Upper Ring 0.23-0.39mm (0.009-0.015 inch) 0.43mm (0.0017 inch) Intermediate Ring0.40-0.66mm (0.015-0.026 inch) 0.74mm (0.029 inch) Oil Control Ring (Steel Rail) 0.028-0.79mm (0.011 - 0.031 inch) 1.55mm (0.061 inch) 7. The No. 1 and No. 2 piston rings have a different cross section. Ensure No. 2 ring is installed with manufacturers I.D. mark (Dot) facing up, towards top of the piston. NOTE: Piston rings are installed in the following order: - Oil ring expander. - Upper oil ring side rail. - Lower oil ring side rail. - No. 2 Intermediate piston ring. - No. 1 Upper piston ring. 8. Install the oil ring expander. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1479 9. Install upper side rail (Fig. 79) by placing one end between the piston ring groove and the expander ring. Hold end firmly and press down the portion to be installed until side rail is in position. Repeat this step for the lower side rail. 10. Install No. 2 intermediate piston ring using a piston ring installer (Fig. 80). 11. Install No. 1 upper piston ring using a piston ring installer (Fig. 80). 12. Position piston ring end gaps as shown in (Fig. 81). It is important that expander ring gap is at least 45°from the side rail gaps, but not on the piston pin center or on the thrust direction. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions 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 °C (1000 °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. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions > Page 1487 Fuel Pressure Release: Service and Repair Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator Clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Description and Operation Rocker Arm Assembly: Description and Operation DESCRIPTION The rocker arms are steel stampings with an integral roller bearing. The rocker arms incorporate a 2.8 mm (0.11 inch) oil hole in the lash adjuster socket for roller and camshaft lubrication. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Description and Operation > Page 1491 Rocker Arm Assembly: Testing and Inspection DIAGNOSIS AND TESTING-HYDRAULIC LASH ADJUSTER A tappet-like noise may be produced from several items. Check the following items. 1. Engine oil level too high or too low. This may cause aerated oil to enter the adjusters and cause them to be spongy. 2. Insufficient running time after rebuilding cylinder head. Low speed running up to I hour may be required. 3. Turn engine off and let set for a few minutes before restarting. Repeat this several times after engine has reached normal operating temperature. 4. Low oil pressure. 5. The oil restrictor in cylinder head gasket or the oil passage to the cylinder head is plugged with debris. 6. Air ingested into oil due to broken or cracked oil pump pick up. 7. Worn valve guides. 8. Rocker arm ears contacting valve spring retainer. 9. Rocker arm loose, adjuster stuck or at maximum extension and still leaves lash in the system. 10. Oil leak or excessive cam bore wear in cylinder head. 11. Faulty lash adjuster. - Check lash adjusters for sponginess while installed in cylinder head and cam on camshaft at base circle. Depress part of rocker arm over adjuster. Normal adjusters should feel very firm. Spongy adjusters can be bottomed out easily. - Remove suspected lash adjusters, and replace. - Before installation, make sure adjusters are at least partially full of oil. This can be verified by little or no plunger travel when lash adjuster is depressed. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Description and Operation > Page 1492 Rocker Arm Assembly: Service and Repair REMOVAL NOTE: Disconnect the battery negative cable to prevent accidental starter engagement. 1. Remove the cylinder head cover. 2. For rocker arm removal on cylinders 3 and 5 Rotate the crankshaft until cylinder # 1 is at TDC exhaust stroke. 3. For rocker arm removal on cylinders 2 and 8 Rotate the crankshaft until cylinder # 1 is at TDC compression stroke. 4. For rocker arm removal on cylinders 4 and 6 Rotate the crankshaft until cylinder # 3 is at TDC compression stroke. 5. For rocker arm removal on cylinders 1 and 7 Rotate the crankshaft until cylinder # 2 is at TDC compression stroke. 6. Using special tool 8516 Rocker Arm Remover, press downward on the valve spring, remove rocker arm (Fig. 45). INSTALLATION CAUTION: Make sure the rocker arms are installed with the concave pocket over the lash adjusters. Failure to do so may cause severe damage to the rocker arms and/or lash adjusters. NOTE: Coat the rocker arms with clean engine oil prior to installation. 1. For rocker arm installation on cylinders 3 and 5 Rotate the crankshaft until cylinder # 1 is at TDC exhaust stroke. 2. For rocker arm installation on cylinders 2 and 8 Rotate the crankshaft until cylinder # 1 is at TDC compression stroke. 3. For rocker arm installation on cylinders 4 and 6 Rotate the crankshaft until cylinder # 3 is at TDC compression stroke. 4. For rocker arm installation on cylinders 1 and 7 Rotate the crankshaft until cylinder # 2 is at TDC compression stroke. 5. Using special tool 8516 press downward on the valve spring, install rocker arm (Fig. 45). 6. Install the cylinder head cover. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications Valve Cover: Specifications Cylinder Head Cover Bolts 105 in.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications > Page 1496 Valve Cover: Description and Operation DESCRIPTION The cylinder head covers are made of die cast magnesium, and are not interchangeable from side-to-side It is imperative that nothing rest on the cylinder head covers. Prolonged contact with other items may wear a hole in the cylinder head cover. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications > Page 1497 Valve Cover: Service and Repair REMOVAL - RIGHT SIDE 1. Disconnect battery negative cable. 2. Remove air cleaner assembly, resonator assembly and air inlet hose. 3. Drain cooling system. 4. Remove accessory drive belt. 5. Remove air conditioning compressor retaining bolts and move compressor to the left. 6. Remove heater hoses. 7. Disconnect injector and ignition coil connectors. 8. Disconnect and remove positive crankcase ventilation (PCV) hose. 9. Remove oil fill tube. 10. Un-clip injector and ignition coil harness and move away from cylinder head cover. 11. Remove right rear breather tube and filter assembly. 12. Remove cylinder head cover retaining bolts. 13. Remove cylinder head cover. NOTE: The gasket may be used again, provided no cuts, tears, or deformation has occurred. REMOVAL - LEFT SIDE 1. Disconnect negative cable from battery. 2. Remove the resonator assemble and air inlet hose. 3. Disconnect injector connectors and un-clip the injector harness. 4. Route injector harness to front of cylinder head cover. 5. Disconnect the left side breather tube and remove the breather tube. 6. Remove the cylinder head cover mounting bolts. 7. Remove cylinder head cover and gasket. NOTE: The gasket may be used again, provided no cuts, tears, or deformation has occurred. CLEANING Clean cylinder head cover gasket surface. Clean head rail, if necessary. INSTALLATION - RIGHT SIDE CAUTION: Do not use harsh cleaners to clean the cylinder head covers. Severe damage to covers may occur. CAUTION: DO NOT allow other components including the wire harness to rest on or against the engine cylinder head cover. Prolonged contact with other objects may wear a hole in the cylinder head cover. 1. Clean cylinder head cover and both sealing surfaces. Inspect and replace gasket as necessary. 2. Install cylinder head cover and hand start all fasteners. Verify that all double ended studs are in the correct location shown in (Fig. 42). 3. Tighten cylinder head cover bolts and double ended studs to 12 Nm (105 in. lbs.). 4. Install right rear breather tube and filter assembly. 5. Connect injector, ignition coil electrical connectors and harness retaining clips. 6. Install the oil fill tube. 7. Install PCV hose. 8. Install heater hoses. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications > Page 1498 9. Install air conditioning compressor retaining bolts. 10. Install accessory drive belt. 11. Fill Cooling system. 12. Install air cleaner assembly, resonator assembly and air inlet hose. 13. Connect battery negative cable. INSTALLATION-LEFT SIDE CAUTION: Do not use harsh cleaners to clean the cylinder head covers. Severe damage to covers may occur. CAUTION: DO NOT allow other components including the wire harness to rest on or against the cylinder head cover. Prolonged contact with other objects may wear a hole In the engine cylinder head cover. 1. Clean cylinder head cover and both sealing surfaces. Inspect and replace gasket as necessary. 2. Install cylinder head cover and hand start all fasteners. Verify that all studs are in the correct location shown in (Fig. 43). 3. Tighten cylinder head cover bolts and double ended studs to 12 Nm (105 in. lbs.). 4. Install left side breather and connect breather tube. 5. Connect injector electrical connectors and injector harness retaining clips. 6. Install the resonator and air inlet hose. 7. Connect negative cable to battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Valve Seat Angle 44.5 - 45.0 deg Runout (MAX) 0.002 in Width Intake 0.069 - 0.0928 in Exhaust 0.0673 - 0.0911 in Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications Free Length (Approx) Intake and Exhaust 1.9134 in Spring Force (Valve Closed) Intake and Exhaust 70.92722 - 79.24515 lbf at 1.6099 in Spring Force (Valve Open) Intake and Exhaust 176.6998 - 193.3357 lbf at 1.167 in Number of Coils Intake and Exhaust 6.69 Wire Diameter Intake and Exhaust 0.1685 - 0.1715 in Installed Height Nominal Intake 1.613 in Spring seat to bottom of retainer. Exhaust 1.606 in Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 1505 Valve Spring: Description and Operation DESCRIPTION The valve springs are made from high strength chrome silicon steel. The springs are common for intake and exhaust applications. The valve spring seat is integral with the valve stem seal, which is a positive type seal to control lubrication. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 1506 Valve Spring: Service and Repair REMOVAL 1. Remove the cylinder head cover. 2. Using Special Tool 8516 Rocker Arm Remover, remove the rocker arms and the hydraulic lash adjusters (Fig. 46). 3. Remove the spark plug for the cylinder the valve spring and seal are to be removed from. 4. Apply shop air to the cylinder to hold the valves in place when the spring is removed 5. Remove the camshaft. NOTE: All eight valve springs and seals are removed in the same manner; this procedure only covers one valve seal and valve spring. 6. Using Special Tool 8387 Valve Spring Compressor, compress the valve spring. NOTE: It may be necessary to tap the top of the valve spring to loosen the spring retainers locks enough to be removed. 7. Remove the two spring retainer lock halves. NOTE: the valve spring is under tension use care when releasing the valve spring compressor. 8. Remove the valve spring compressor. 9. Remove the spring retainer, and the spring. 10. Remove the valve stem seal. NOTE: The valve stem seals are common between intake and exhaust. INSTALLATION Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 1507 1. coat the valve stem with clean engine oil and install the valve stem seal. Make sure the seal is fully seated and that the garter spring at the top of the seal is intact. 2. Install the spring and the spring retainer (Fig. 47). 3. Using Special Tool 8387 Valve Spring Compressor, compress the spring and install the two valve spring retainer halves. 4. Release the valve spring compressor and make sure the two spring retainer halves and the spring retainer are fully seated. 5. Install the camshaft. 6. Position the hydraulic lash adjusters and rocker arms (Fig. 46). 7. Install the cylinder head cover. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Description and Operation Valve: Description and Operation DESCRIPTION The valves are made of heat resistant steel and have chrome plated stems to prevent scuffing. Each valve is actuated by a roller rocker arm which pivots on a stationary lash adjuster. All valves use three bead lock keepers to retain the springs and promote valve rotation. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Description and Operation > Page 1511 Valve: Service and Repair STANDARD PROCEDURE-REFACING NOTE: Valve seats that are worn or burned can be reworked, provided that correct angle and seat width are maintained. Otherwise the cylinder head must be replaced. NOTE: When refacing valves and valve seats, it is important that the correct size valve guide pilot be used for reseating stones. A true and complete surface must be obtained. 1. Using a suitable dial indicator measure the center of the valve seat Total run out must not exceed 0.051 mm (0.002 inch). 2. Apply a small amount of Prussian blue to the valve seat, insert the valve into the cylinder head, while applying light pressure on the valve rotate the valve. Remove the valve and examine the valve face. If the blue is transferred below the top edge of the valve face, lower the valve seat using a 15 degree stone. If the blue is transferred to the bottom edge of the valve face, raise the valve seat using a 65 degree stone. 3. When the seat is properly positioned the width of the intake seat must be 1.75 - 2.36 mm. (0.0689 0.0928 inch) and the exhaust seat must be 1.71 2.32 mm (0.0673 - 0.0911 inch). 4. Check the valve spring installed height after refacing the valve and seat. The installed height for both intake and exhaust valve springs must not exceed 41.44 mm. (1.6315 inch). 5. The valve seat and valve face must maintain a face angle of 44.5 - 45 degrees angle (Fig. 44). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection Drive Belt: Testing and Inspection VISUAL DIAGNOSIS When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface of the belt from rib to rib (Fig. 9), are considered normal. These are not a reason to replace the belt. However, cracks running along a rib (not across) are not normal. Any belt with cracks running along a rib must be replaced (Fig. 9). Also replace the belt if it has excessive wear, frayed cords or severe glazing. Refer to ACCESSORY DRIVE BELT DIAGNOSIS CHART for further belt diagnosis. NOISE DIAGNOSIS Noises generated by the accessory drive belt are most noticeable at idle. Before replacing a belt to resolve a noise condition, inspect all of the accessory drive pulleys for alignment, glazing, or excessive end play. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 1516 ACCESSORY DRIVE BELT DIAGNOSIS CHART Part 1 of 2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 1517 ACCESSORY DRIVE BELT DIAGNOSIS CHART Part 2 of 2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 1518 Drive Belt: Service and Repair REMOVAL CAUTION: DO NOT LET TENSIONER ARM SNAP BACK TO THE FREE ARM POSITION, SEVER DAMAGE MAY OCCUR TO THE TENSIONER. Belt tension is not adjustable. Belt adjustment is maintained by an automatic (spring load) belt tensioner. 1. Disconnect negative battery cable from battery. 2. Rotate belt tensioner until it contacts it's stop. Remove belt, then slowly rotate the tensioner into the free arm position. (Fig. 10). INSTALLATION Belt tension is not adjustable. Belt adjustment is maintained by an automatic (spring load) belt tensioner. 1. Check condition of all pulleys. CAUTION: When installing the serpentine accessory drive belt, the belt MUST be routed correctly. If not, the engine may overheat due to the water pump rotating in the wrong direction (Fig. 10). 2. Install new belt (Fig. 10). Route the belt around all pulleys except the idler pulley. Rotate the tensioner arm until it contacts it's stop position. Route the belt around the idler and slowly let the tensioner rotate into the belt. Make sure the belt is seated onto all pulleys. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 1519 3. With the drive belt installed, inspect the belt wear indicator (Fig. 11). On 4.7L Engines only, the gap between the tang and the housing stop (measurement A) must not exceed 24 mm. (0.94 inches). If the measurement exceeds this specification replace the serpentine accessory drive belt. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Description and Operation Drive Belt Tensioner: Description and Operation DESCRIPTION Correct drive belt tension is required to ensure optimum performance of the belt driven engine accessories. If specified tension is not maintained, belt slippage may cause; engine overheating, lack of power steering assist, loss of air conditioning capacity, reduced generator output rate, and greatly reduced belt life. It is not necessary to adjust belt tension on the 4.7L engine. These engines are equipped with an automatic belt tensioner (Fig. 3). The tensioner maintains correct belt tension at all times. Due to use of this belt tensioner, do not attempt to use a belt tension gauge on 4.7L engines. OPERATION The automatic belt tensioner maintains belt tension by using internal spring pressure, a pivoting arm and pulley to press against the drive belt. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Description and Operation > Page 1523 Drive Belt Tensioner: Service and Repair REMOVAL On 4.7L engines, the tensioner is equipped with an indexing tang on back of tensioner and an indexing stop on tensioner housing. If a new belt is being installed, tang must be within approximately 24 mm. (0.94 inches) of indexing stop. Belt is considered new if it has been used 15 minutes or less. If the above specification cannot be met, check for: The wrong belt being installed (incorrect length/ width) - Worn bearings on an engine accessory (A/C compressor, power steering pump, water pump, idler pulley or generator) - A pulley on an engine accessory being loose - Misalignment of an engine accessory - Belt incorrectly routed. NOTE: A used belt should be replaced if tensioner indexing arrow has moved to the minimum tension indicator. Tensioner travel stops at this point. 1. Remove accessory drive belt. 2. Remove tensioner assembly from mounting bracket (Fig. 4). WARNING: BECAUSE OF HIGH SPRING PRESSURE, DO NOT ATTEMPT TO DISASSEMBLE AUTOMATIC TENSIONER. UNIT IS SERVICED AS AN ASSEMBLY EXCEPT FOR PULLEY ON TENSIONER. 3. Remove pulley bolt. Remove pulley from tensioner. INSTALLATION 1. Install pulley and pulley bolt to tensioner. Tighten bolt to 61 Nm (45 ft. lbs.) torque. 2. An indexing slot is located on back of tensioner. Align this slot to the head of the bolt on the front cover. Install the mounting bolt. Tighten bolt to 41 Nm (30 ft. lbs.). 3. Install accessory drive belt. 4. Check belt indexing marks (Fig. 3). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 REMOVAL 1. Disconnect the negative cable from the battery. CAUTION: Remove the fan blade, fan clutch and fan shroud before raising engine. Failure to do so may cause damage to the fan blade, fan clutch and fan shroud. 2. Remove the fan blade, fan clutch and fan shroud. 3. Remove the engine oil filter. 4. Support the engine with a suitable jack and a block of wood across the full width of the engine oil pan. 5. Remove the four (4) cylinder block-to-insulator mount bolts and the nut from the engine insulator mount through bolt (4x2 Vehicles only) (Fig. 88) (Fig. 89). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 1528 6. Remove the three (3) cylinder block-to-insulator mount bolts and loosen the nut from the engine insulator mount through bolt (4x4 Vehicles only) (Fig. 90) (Fig. 9 1). 7. Using the jack, raise the engine high enough to remove the engine insulator mount through bolt and the insulator mount. INSTALLATION 1. Position the insulator mount and install the insulator mount through bolt. 2. Lower the engine until the four cylinder block-to-insulator mount bolts can be installed. 3. Remove the jack and block of wood. 4. Torque the cylinder block-to-insulator mount bolts to 61 Nm ( 45 ft. lbs.). 5. Install and torque the through bolt retaining nut to 61 Nm (45 ft. lbs.). 6. Install the fan blade, fan clutch and fan shroud. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 1529 Engine Mount: Service and Repair Rear Mount REAR MOUNT REMOVAL 1. Raise vehicle on hoist. 2. Using a suitable jack, support transmission. 3. Remove the nut from the insulator mount through bolt (Manual transmission and 4x2 automatic transmission only) (Fig. 92) (Fig. 93). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 1530 4. Remove the four bolts and washers retaining the mount to the transmission (4x4 automatic transmission only) (Fig. 94). 5. Raise the transmission enough to remove the through bolt (Manual transmission and 4x2 automatic transmission only) (Fig. 92) (Fig. 93). 6. Raise the transmission and remove the bolts retaining the mount to the crossmember (4x4 automatic transmission only) (Fig. 94). 7. Remove the two nuts retaining the isolator to the crossmember (Manual transmission and 4x2 automatic transmission only) (Fig. 92) (Fig. 93). 8. Remove the bolts (two bolts manual transmission)(three bolts 4x2 automatic transmission) retaining the insulator bracket to the transmission. INSTALLATION 1. Follow the removal procedure in the reverse order. 2. Tighten the through bolt retaining nut to 101 Nm (75 ft. lbs.). 3. retighten the isolator bracket to transmission retaining bolts (Manual transmission and 4x2 automatic transmission only) to 68 Nm (50 ft. lbs.). 4. Tighten the mount bracket to transmission retaining bolts (4x4 automatic transmission only) to 68 Nm (50 ft. lbs.). 5. Tighten the isolator mount to crossmember retaining nuts (Manual transmission and 4x2 automatic transmission only) to 41 Nm (30 ft. lbs.). 6. Tighten the mount bracket to crossmember retaining bolts (4x4 automatic transmission only) to 28 Nm (250 in. lbs.). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications OIL PRESSURE @ Curb Idle Speed (Minimum) 4 psi CAUTION: If pressure is ZERO at curb idle, DO NOT run engine at 3000 rpm. @ 3000 rpm 25 - 110 psi Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Additives/Supplements Engine Oil: Technical Service Bulletins Engine Oil - Additives/Supplements NUMBER: 09-003-01 GROUP: Engine DATE: May 4, 2001 SUBJECT: Engine Oil Additives/Supplements OVERVIEW: This bulletin reinforces a requirement to cease the current practice of using supplemental oil additive treatments in all DaimlerChrysler engines. MODELS: 2001 (AB) Ram Van/Wagon 2001 (AN) Dakota 2001 (BR/BE) Ram Pickup 2001 (DN) Durango 2001 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 2002 (KJ) Liberty 2001 (LH) Concorde/Intrepid/LHS/300M 2001 (PL) Neon 2001 (PR) Prowler 2001 (PT) PT Cruiser 2001 (RG) Chrysler Voyager (International Markets) 2001 (RS) Town & Country/Caravan/Voyager 2001 (ST) Sebring Coupe 2001 (SR) Viper 2001 (TJ) Wrangler 2001 (WG) Grand Cherokee (International Markets) 2001 (WJ) Grand Cherokee 2001 (XJ) Cherokee NOTE: THIS BULLETIN APPLIES TO ALL DAIMLERCHRYSLER MODELS/ENGINES BUILT BEFORE AND AFTER THE 2001 MODEL YEAR. DISCUSSION Engine oil additives/supplements (EOS) should not be used to enhance engine oil performance. Engine oil additives/supplements should not be used to extend engine oil change intervals. No additive is known to be safe for engine durability and can degrade emission components. Additives can contain undesirable materials that harm the long term durability of engines by: ^ Doubling the level of Phosphorus in the engine oil. The ILSAC (International Lubricant Standard Approval Committee) GF-2 and GF-3 standards require that engine oil contain no more than 0.10% Phosphorus to protect the vehicles emissions performance. Addition of engine oil additives/supplements can poison, from the added sulfur and phosphorus, catalysts and hinder efforts to guarantee our emissions performance to 80,000 miles and new requirements of 150,000 miles. ^ Altering the viscosity characteristics of the engine oil so that it no longer meets the requirements of the specified viscosity grade. ^ Creating potential for an undesirable additive compatibility interaction in the engine crankcase. Generally it is not desirable to mix additive packages from different suppliers in the crankcase; there have been reports of low temperature engine failures caused by additive package incompatibility with such mixtures. POLICY: Information Only Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil Capacity w/filter .................................................................................................................. ....................................................................... 6.0 Qt Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1541 Engine Oil: Fluid Type Specifications Engine Oil Type ................................................................................................................................... ................................... 5W-30 SAE or 10W-30 SAE Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1542 Engine Oil: Service Precautions SAFETY PRECAUTIONS WARNING: Prolonged and repeated contact with used engine oil may cause skin cancer. Avoid prolonged and repeated contact with oils, particularly used engine oils. - Wear protective clothing, including impervious gloves where practicable. - Do not put oily rags in pockets. - Avoid contaminating clothes, particularly underpants, with oil. - Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly. - First Aid treatment should be obtained immediately for open cuts and wounds. - Use barrier creams, applying them before each work period, to help the removal of oil from the skin. - Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. - Do not use gasoline, kerosine, diesel fuel, gas oil, thinner or solvents for cleaning skin. - If skin disorders develop, obtain medical advice without delay. - Where practicable, degrease components prior to handling. - Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1543 Engine Oil: Service and Repair STANDARD PROCEDURE - ENGINE OIL SERVICE WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER. DO NOT WASH SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. ENGINE OIL SPECIFICATION CAUTION: Do not use non-detergent or straight mineral oil when adding or changing crankcase lubricant. Engine failure can result. API SERVICE GRADE CERTIFIED Use an engine oil that is API Service Grade Certified. MOPAR provides engine oils that conform to this service grade. SAE VISCOSITY An SAE viscosity grade is used to specify the viscosity of engine oil. Use only engine oils with multiple viscosities such as 5W-30 or 1OW-30 in the 4.7L engines. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your particular temperature range and variation (Fig. 97). ENERGY CONSERVING OIL An Energy Conserving type oil is recommended for gasoline engines. The designation of ENERGY CONSERVING is located on the label of an engine oil container. CONTAINER IDENTIFICATION Standard engine oil identification notations have been adopted to aid in the proper selection of engine oil. The identifying notations are located on the label of engine oil plastic bottles and the top of engine oil cans (Fig. 98). OIL LEVEL INDICATOR (DIPSTICK) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1544 The engine oil level indicator is located at the right rear of the engine on the 4.7L engines. (Fig. 99). CRANKCASE OIL LEVEL INSPECTION CAUTION: Do not overfill crankcase with engine oil, pressure loss or oil foaming can result. Inspect engine oil level approximately every 800 kilometers (500 miles). Unless the engine has exhibited loss of oil pressure, run the engine for about five minutes before checking oil level. Checking engine oil level on a cold engine is not accurate. To ensure proper lubrication of an engine, the engine oil must be maintained at an acceptable level. The acceptable levels are indicated between the ADD and SAFE marks on the engine oil dipstick. 1. Position vehicle on level surface. 2. With engine OFF, allow approximately ten minutes for oil to settle to bottom of crankcase, remove engine oil dipstick. 3. Wipe dipstick clean. 4. Install dipstick and verify it is seated in the tube. 5. Remove dipstick, with handle held above the tip, take oil level reading. 6. Add oil only if level is below the ADD mark on dipstick. ENGINE OIL CHANGE Change engine oil at mileage and time intervals described in Maintenance Schedules. Run engine until achieving normal operating temperature. 1. Position the vehicle on a level surface and turn engine off. 2. Hoist and support vehicle on safety stands. 3. Remove oil fill cap. 4. Place a suitable drain pan under crankcase drain. 5. Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug if damaged. 6. Install drain plug in crankcase. 7. Lower vehicle and fill crankcase with specified type and amount of engine oil. 8. Install oil fill cap. 9. Start engine and inspect for leaks. 10. Stop engine and inspect oil level. USED ENGINE OIL DISPOSAL Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Locations > Page 1548 Oil Filter: Service and Repair REMOVAL All engines are equipped with a high quality full flow, disposable type oil filter. Daimler Chrysler Corporation recommends a Mopar or equivalent oil filter be used. 1. Position a drain pan under the oil filter. 2. Using a suitable oil filter wrench loosen filter. 3. Rotate the oil filter counterclockwise (Fig. 100) to remove it from the cylinder block oil filter boss. 4. When filter separates from cylinder block oil filter boss, tip gasket end upward to minimize oil spill. Remove filter from vehicle. NOTE: Make sure filter gasket was removed with filter. 5. With a wiping cloth, clean the gasket sealing surface of oil and grime. INSTALLATION 1. Lightly lubricate oil filter gasket with engine oil. 2. Thread filter onto adapter nipple. When gasket makes contact with sealing surface, (Fig. 101) hand tighten filter one full turn, do not over tighten. 3. Add oil, verify crankcase oil level and start engine. Inspect for oil leaks. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil Pan Bolts 130 in.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1552 Oil Pan: Service and Repair REMOVAL--4X2 1. Drain the cooling system. 2. Remove the upper fan shroud. 3. Remove the throttle body resonator and air inlet hose. 4. Remove the intake manifold. 5. Raise vehicle on hoist. 6. Disconnect exhaust pipe at exhaust manifolds. 7. Remove the structural dust cover (Fig. 102) using sequence shown. 8. Drain engine oil and remove oil filter. 9. Position suitable jack under engine. 10. Remove both left and right side engine mount through bolts (Fig. 103). 11. Raise engine to provide clearance to remove oil pan. 12. Place blocks of wood between engine brackets and lower mounts to provide stability to engine. NOTE: Do not pry on oil pan or oil pan gasket. Gasket is mounted to engine and does not come out with oil pan. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1553 13. Remove the oil pan mounting bolts and oil pan (Fig. 104). 14. Unbolt oil pump pickup tube and remove tube and oil pan gasket from engine. REMOVAL NOTE: 4X4 vehicles equipped with a 4.71- engine must have the front axle removed before the oil pan can be removed. 1. Remove the front axle from vehicle. 2. Remove the structural dust cover (Fig. 105) using sequence shown. 3. Drain the engine oil and remove oil filter. NOTE: Do not pry on oil pan or oil pan gasket. Gasket is mounted to engine and does not come out with oil pan. 4. Remove the oil pan mounting bolts and oil pan (Fig. 106). 5. Unbolt oil pump pickup tube and remove tube and oil pan gasket from engine. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1554 INSTALLATION 1. Clean the oil pan gasket mating surface of the bedplate and oil pan. 2. Position the oil pan gasket and pickup tube with new O-ring. Install the mounting bolt and nuts. Tighten bolt and nuts to 28 Nm (20 ft. lbs.). 3. Position the oil pan and install the mounting bolts. Tighten the mounting bolts to 15 Nm (11 ft. lbs.) in the sequence shown (Fig. 104). 4. Raise the engine and remove the blocks of wood. 5. Lower engine and install both the left and right side engine mount through bolts (Fig. 103). Tighten the nuts to 68 Nm (50 ft. lbs.). 6. Remove jack and install oil filter. 7. Install structural dust cover. 8. Install exhaust pipe onto exhaust manifolds. 9. Lower vehicle. 10. Install intake manifold. 11. Install throttle body resonator and air inlet hose. 12. Install upper fan shroud. 13. Fill cooling system. 14. Fill engine oil. 15. Start engine and check for leaks. INSTALLATION 1. Clean the oil pan gasket mating surface of the bedplate and oil pan. 2. Position the oil pan gasket and pickup tube with new O-ring. Install the mounting bolt and nuts. Tighten bolt and nuts to 28 Nm (20 ft. lbs.). 3. Position the oil pan and install the mounting bolts. Tighten the mounting bolts to 15 Nm (11 ft. lbs.) in the sequence shown (Fig. 106). 4. Install structural dust cover. 5. Install oil filter. 6. Install front axle. 7. Lower vehicle. 8. Fill engine oil. 9. Start engine check for leaks. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Locations Oil Pressure Gauge: Locations The oil pressure gauge is located in the upper right quadrant of the instrument cluster, above the fuel gauge. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Locations > Page 1558 Oil Pressure Gauge: Description and Operation An oil pressure gauge is standard equipment on all instrument clusters. The oil pressure gauge is located in the upper right quadrant of the instrument cluster, above the fuel gauge. The oil pressure gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from "L" (or Low) to "H" (or High). An International Control and Display Symbol icon for "Engine Oil" is located on the cluster overlay, in the center of the gauge directly above the hub of the gauge needle. The oil pressure gauge graphics are white against a black field except for a single red graduation at the low end of the gauge scale, making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned ON, the white graphics appear blue-green and the red graphics appear red. The orange gauge needle is internally illuminated. Gauge illumination is provided by replaceable incandescent bulb and bulb holder units located on the instrument cluster electronic circuit board. The oil pressure gauge is serviced as a unit with the instrument cluster. The oil pressure gauge gives an indication to the vehicle operator of the engine oil pressure. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The oil pressure gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Oil Pressure Message - The instrument cluster circuitry restricts the oil pressure gauge needle operation in order to provide readings that are consistent with customer expectations. Each time the cluster receives a message from the PCM indicating the engine oil pressure is between about 6.9 kPa (1 psi) and 137.9 kPa (20 psi), the cluster holds the gauge needle at a point about 11 degrees above the low end of normal increment on the gauge scale. Each time the cluster receives a message from the PCM indicating the engine oil pressure is between about 517.1 kPa (75 psi) and 755 kPa (109.5 psi), the cluster holds the gauge needle at a point about 7.4 degrees below the high end of normal increment on the gauge scale. When the cluster receives messages from the PCM indicating the engine oil pressure is between about 137.9 kPa (20 psi) and 517.1 kPa (75 psi), the gauge needle is moved to the actual pressure position on the gauge scale. - Engine Oil Pressure Low Message - Each time the cluster receives a message from the PCM indicating the engine oil pressure is below about 6.9 kPa (1 psi), the gauge needle is moved to the L (Low) graduation at the far left end of the gauge scale, the check gauges indicator is illuminated, and a single chime tone is generated. The gauge needle remains at the low end of the scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM indicating that the engine oil pressure is above about 6.9 kPa (1 psi), or until the ignition switch is turned to the OFF position, whichever occurs first. The cluster will only turn the check gauges indicator lamp ON in response to an engine oil pressure low message if the engine speed message is greater than zero. - Engine Oil Pressure High Message - Each time the cluster receives a message from the PCM indicating the engine oil pressure is above about 755 kPa (109.5 psi), the gauge needle is moved to the H (High) graduation at the far right end of the gauge scale. The gauge needle remains at the high end of the scale until the cluster receives a message from the PCM indicating that the engine oil pressure is below about 755 kPa (109.5 psi), or until the ignition switch is turned to the OFF position, whichever occurs first. - Message Failure - If the cluster fails to receive an engine oil pressure message, it will hold the gauge needle at the last indication until a new message is received, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM continually monitors the engine oil pressure sensor to determine the engine oil pressure. The PCM then sends the proper engine oil pressure messages to the instrument cluster. For further diagnosis of the oil pressure gauge or the instrument cluster circuitry that controls the gauge, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). If the instrument cluster turns ON the check gauges indicator due to a low oil pressure gauge reading, it may indicate that the engine or the engine oiling system requires service. For proper diagnosis of the engine oil pressure sensor, the PCM, the PCI data bus, or the message inputs to the instrument cluster that control the oil pressure gauge, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams Engine Oil Pressure Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Page 1562 Oil Pressure Sensor: Description and Operation DESCRIPTION The 2-wire, electrical/mechanical engine oil pressure sensor (sending unit) is located in an engine oil pressure gallery. OPERATION The oil pressure sensor uses two circuits. They are: ^ A signal to the PCM relating to engine oil pressure ^ A sensor ground through the PCM's sensor return The oil pressure sensor returns a voltage signal back to the PCM relating to engine oil pressure. This signal is then transferred (bussed) to the instrument panel on a CCD bus circuit to operate the oil pressure gauge and the check gauges lamp. Ground for the sensor is provided by the PCM through a low noise sensor return. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Page 1563 Oil Pressure Sensor: Service and Repair REMOVAL 1. Disconnect the negative cable from the battery. 2. Raise vehicle on hoist. 3. Remove front splash shield. 4. Disconnect oil pressure sender wire (Fig. 107). 5. Remove the pressure sender (Fig. 107). INSTALLATION 1. Install oil pressure sender. 2. Connect oil pressure sender wire. 3. Install front splash shield. 4. Lower vehicle. 5. Connect the negative battery cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Application and ID Oil Pressure Warning Lamp/Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Engine Oil Pressure ............................................................................................................................. ............................................................... PC194 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications OIL PRESSURE @ Curb Idle Speed (Minimum) 4 psi CAUTION: If pressure is ZERO at curb idle, DO NOT run engine at 3000 rpm. @ 3000 rpm 25 - 110 psi Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Intake Manifold Torque Specifications Intake Manifold: Specifications Intake Manifold Torque Specifications Tighten intake manifold retaining bolts in sequence shown to 12 Nm (105 in. lbs.). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Intake Manifold Torque Specifications > Page 1575 Intake Manifold: Specifications Throttle Body Bolt Torque Specifications Throttle Body Mounting Bolts .............................................................................................................................................................. 12 Nm (105 in. lbs.) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1576 Intake Manifold: Description and Operation DESCRIPTION The intake manifold is made of a composite material and features long runners which maximizes low end torque. The intake manifold uses single plane sealing which consist of eight individual press in place port gaskets to prevent leaks. Eight studs and two bolts are used to fasten the intake to the head. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1577 Intake Manifold: Testing and Inspection DIAGNOSIS AND TESTING-INTAKE MANIFOLD LEAKAGE An intake manifold air leak is characterized by lower than normal manifold vacuum. Also, one or more cylinders may not be functioning. WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR THE FAN. DO NOT WEAR LOOSE CLOTHING. 1. Start the engine. 2. Spray a small stream of water at the suspected leak area. 3. If a change in RPM is observed the area of the suspected leak has been found. 4. Repair as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Intake Manifold: Service and Repair Intake Manifold REMOVAL 1. Disconnect negative cable from battery. 2. Remove resonator assembly and air inlet hose. 3. Disconnect throttle and speed control cables. 4. Disconnect electrical connectors for the following components: - Manifold Absolute Pressure (MAP) Sensor - Intake Air Temperature (IAT) Sensor - Throttle Position (TPS) Sensor - Coolant Temperature (CTS) Sensor - Idle Air Control (IAC) Motor 5. Disconnect brake booster hose and positive crankcase ventilation (PCV) hose. 6. Disconnect generator electrical connections. 7. Disconnect air conditioning compressor electrical connections. 8. Disconnect left and right radio suppressor straps. 9. Disconnect and remove ignition coil towers. 10. Remove top oil dipstick tube retaining bolt and ground strap. 11. Bleed fuel system. 12. Remove fuel rail. 13. Remove throttle body assembly and mounting bracket. 14. Drain cooling system below coolant temperature level. 15. Remove the heater hoses from the engine front cover and the heater core. 16. Unclip and remove heater hoses and tubes from intake manifold (Fig. 115). 17. Remove coolant temperature sensor. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold > Page 1580 18. Remove intake manifold retaining fasteners in reverse order of tightening sequence (Fig. 116). 19. Remove intake manifold. INSTALLATION 1. Install intake manifold gaskets. 2. Position intake manifold. 3. Install intake manifold retaining bolts and tighten in sequence shown in (Fig. 117) to 12 Nm (105 in. lbs.). 4. Install left and right radio suppressor straps. 5. Install throttle body assembly. 6. Install throttle cable bracket. 7. Connect throttle cable and speed control cable to throttle body. 8. Install fuel rail. 9. Install ignition coil towers. 10. Position and install heater hoses and tubes onto intake manifold. 11. Install the heater hoses to the heater core and engine front cover. 12. Connect electrical connectors for the following components: - Manifold Absolute Pressure (MAP) Sensor - Intake Air Temperature (IAT) Sensor - Throttle Position UPS) Sensor - Coolant Temperature (CTS) Sensor - Idle Air Control (IAC) Motor - Ignition coil towers - Fuel injectors Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold > Page 1581 13. Install top oil dipstick tube retaining bolt and ground strap. 14. Connect generator electrical connections. 15. Connect Brake booster hose and Positive crankcase ventilation (PCV) hose. 16. Fill cooling system. 17. Install resonator assembly and air inlet hose. 18. Connect negative cable to battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold > Page 1582 Intake Manifold: Service and Repair Cleaning and Inspection CLEANING NOTE: There is NO approved repair procedure for the intake manifold. If severe damage is found during inspection, the intake manifold must be replaced. Before installing the intake manifold thoroughly clean the mating surfaces. Use a suitable cleaning solvent, then air dry. INSPECTION 1. Inspect the intake sealing surface for cracks, nicks and distortion. 2. Inspect the intake manifold vacuum hose fittings for looseness or blockage. 3. Inspect the manifold to throttle body mating surface for cracks, nicks and distortion. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Locations Oil Pressure Gauge: Locations The oil pressure gauge is located in the upper right quadrant of the instrument cluster, above the fuel gauge. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Locations > Page 1587 Oil Pressure Gauge: Description and Operation An oil pressure gauge is standard equipment on all instrument clusters. The oil pressure gauge is located in the upper right quadrant of the instrument cluster, above the fuel gauge. The oil pressure gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from "L" (or Low) to "H" (or High). An International Control and Display Symbol icon for "Engine Oil" is located on the cluster overlay, in the center of the gauge directly above the hub of the gauge needle. The oil pressure gauge graphics are white against a black field except for a single red graduation at the low end of the gauge scale, making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned ON, the white graphics appear blue-green and the red graphics appear red. The orange gauge needle is internally illuminated. Gauge illumination is provided by replaceable incandescent bulb and bulb holder units located on the instrument cluster electronic circuit board. The oil pressure gauge is serviced as a unit with the instrument cluster. The oil pressure gauge gives an indication to the vehicle operator of the engine oil pressure. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The oil pressure gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Oil Pressure Message - The instrument cluster circuitry restricts the oil pressure gauge needle operation in order to provide readings that are consistent with customer expectations. Each time the cluster receives a message from the PCM indicating the engine oil pressure is between about 6.9 kPa (1 psi) and 137.9 kPa (20 psi), the cluster holds the gauge needle at a point about 11 degrees above the low end of normal increment on the gauge scale. Each time the cluster receives a message from the PCM indicating the engine oil pressure is between about 517.1 kPa (75 psi) and 755 kPa (109.5 psi), the cluster holds the gauge needle at a point about 7.4 degrees below the high end of normal increment on the gauge scale. When the cluster receives messages from the PCM indicating the engine oil pressure is between about 137.9 kPa (20 psi) and 517.1 kPa (75 psi), the gauge needle is moved to the actual pressure position on the gauge scale. - Engine Oil Pressure Low Message - Each time the cluster receives a message from the PCM indicating the engine oil pressure is below about 6.9 kPa (1 psi), the gauge needle is moved to the L (Low) graduation at the far left end of the gauge scale, the check gauges indicator is illuminated, and a single chime tone is generated. The gauge needle remains at the low end of the scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM indicating that the engine oil pressure is above about 6.9 kPa (1 psi), or until the ignition switch is turned to the OFF position, whichever occurs first. The cluster will only turn the check gauges indicator lamp ON in response to an engine oil pressure low message if the engine speed message is greater than zero. - Engine Oil Pressure High Message - Each time the cluster receives a message from the PCM indicating the engine oil pressure is above about 755 kPa (109.5 psi), the gauge needle is moved to the H (High) graduation at the far right end of the gauge scale. The gauge needle remains at the high end of the scale until the cluster receives a message from the PCM indicating that the engine oil pressure is below about 755 kPa (109.5 psi), or until the ignition switch is turned to the OFF position, whichever occurs first. - Message Failure - If the cluster fails to receive an engine oil pressure message, it will hold the gauge needle at the last indication until a new message is received, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM continually monitors the engine oil pressure sensor to determine the engine oil pressure. The PCM then sends the proper engine oil pressure messages to the instrument cluster. For further diagnosis of the oil pressure gauge or the instrument cluster circuitry that controls the gauge, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). If the instrument cluster turns ON the check gauges indicator due to a low oil pressure gauge reading, it may indicate that the engine or the engine oiling system requires service. For proper diagnosis of the engine oil pressure sensor, the PCM, the PCI data bus, or the message inputs to the instrument cluster that control the oil pressure gauge, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Application and ID Oil Pressure Warning Lamp/Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Engine Oil Pressure ............................................................................................................................. ............................................................... PC194 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Testing and Inspection Crankshaft Main Bearing Seal: Testing and Inspection DIAGNOSIS AND TESTING-REAR SEAL AREA LEAKS Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the engine, a more involved inspection is necessary. The following steps should be followed to help pinpoint the source of the leak. If the leakage occurs at the crankshaft rear oil seal area: 1. Disconnect the battery. 2. Raise the vehicle. 3. Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil. Use a black light to check for the oil leak: a. Circular spray pattern generally indicates seal leakage or crankshaft damage. b. Where leakage tends to run straight down, possible causes are a porous block, distributor seal, camshaft bore cup plugs, oil galley pipe plugs, oil filter runoff, and main bearing cap to cylinder block mating surfaces. See Engine, for proper repair procedures of these items. 4. If no leaks are detected, pressurized the crankcase. CAUTION: Do not exceed 20.6 kPa (3 psi). 5. If the leak is not detected, very slowly turn the crankshaft and watch for leakage. If a leak is detected between the crankshaft and seal while slowly turning the crankshaft, it is possible the crankshaft seal surface is damaged. The seal area on the crankshaft could have minor nicks or scratches that can be polished out with emery cloth. CAUTION: Use extreme caution when crankshaft polishing is necessary to remove minor nicks or scratches. The crankshaft seal flange is specially machined to complement the function of the rear oil seal. 6. For bubbles that remain steady with shaft rotation, no further inspection can be done until disassembled. Refer to components inspections on possible causes and corrections. 7. After the oil leak root cause and appropriate corrective action have been identified. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Testing and Inspection > Page 1595 Crankshaft Main Bearing Seal: Service and Repair REMOVAL NOTE: This procedure can be performed in vehicle. 1. If being performed in vehicle, remove the transmission. 2. Remove the flexplate. NOTE: The crankshaft oil seal CAN NOT be reused after removal. NOTE: The crankshaft rear oil seal remover Special Tool 8506 must be installed deeply into the seal. Continue to tighten the removal tool into the seal until the tool can not be turned farther. Failure to install tool correctly the first time will cause tool to pull free of seal without removing seal from engine. 3. Using Special Tool 8506 (Fig. 68), remove the crankshaft rear oil seal. INSTALLATION 1. Position the magnetic seal guide Special Tool 8349-2 (Fig. 69) onto the crankshaft rear face. Then position the crankshaft rear oil seal onto the Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Testing and Inspection > Page 1596 guide. 2. Using Special Tools 8349 Crankshaft Rear Oil Seal Installer and C-4171 Driver Handle (Fig. 70), with a hammer, tap the seal into place. Continue to tap on the driver handle until the seal installer seats against the cylinder block crankshaft bore. 3. Install the flexplate. 4. If removed, install the transmission. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 REMOVAL 1. Disconnect negative cable from battery. 2. Remove accessory drive belt. 3. Remove A/C compressor mounting fasteners and set aside. 4. Drain cooling system. 5. Remove upper radiator hose. 6. Disconnect electrical connector for fan mounted inside radiator shroud. 7. Remove radiator shroud attaching fasteners. NOTE: Transmission cooler line snaps into shroud lower right hand corner. 8. Remove radiator cooling fan and shroud. 9. Remove crankshaft damper bolt. 10. Remove damper using Special Tools 8513 Insert and 1026 Three Jaw Puller (Fig. 65). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 1600 11. Using Special Tool 8511, remove crankshaft front seal (Fig. 66). INSTALLATION CAUTION: To prevent severe damage to the Crankshaft, Damper or Special Tool 8512, thoroughly clean the damper bore and the crankshaft nose before installing Damper. 1. Using Special Tool 8348 and 8512, install crankshaft front seal (Fig. 67). 2. Install vibration damper. 3. Install radiator cooling fan and shroud. 4. Install upper radiator hose. 5. Install A/C compressor and tighten fasteners to 54 Nm (40 ft. lbs.). 6. Install accessory drive belt refer. 7. Refill cooling system. 8. Connect negative cable to battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Description and Operation Valve Guide Seal: Description and Operation DESCRIPTION The valve stem seals are made of rubber and incorporate an integral steel valve spring seat. The integral garter spring maintains consistent lubrication control to the valve stems. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams Engine Oil Pressure Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Page 1608 Oil Pressure Sensor: Description and Operation DESCRIPTION The 2-wire, electrical/mechanical engine oil pressure sensor (sending unit) is located in an engine oil pressure gallery. OPERATION The oil pressure sensor uses two circuits. They are: ^ A signal to the PCM relating to engine oil pressure ^ A sensor ground through the PCM's sensor return The oil pressure sensor returns a voltage signal back to the PCM relating to engine oil pressure. This signal is then transferred (bussed) to the instrument panel on a CCD bus circuit to operate the oil pressure gauge and the check gauges lamp. Ground for the sensor is provided by the PCM through a low noise sensor return. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Page 1609 Oil Pressure Sensor: Service and Repair REMOVAL 1. Disconnect the negative cable from the battery. 2. Raise vehicle on hoist. 3. Remove front splash shield. 4. Disconnect oil pressure sender wire (Fig. 107). 5. Remove the pressure sender (Fig. 107). INSTALLATION 1. Install oil pressure sender. 2. Connect oil pressure sender wire. 3. Install front splash shield. 4. Lower vehicle. 5. Connect the negative battery cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Torque Torque Camshaft Non-Oiled Sprocket Bolt 90 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Specifications Crankshaft Gear/Sprocket: Specifications Crankshaft Damper Bolt 130 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications Timing Chain: Specifications Camshaft Non-Oiled Sprocket Bolt 90 ft.lb Crankshaft Damper Bolt 130 ft.lb Timing Chain Cover Bolts 40 ft.lb Timing Chain Guide Bolts 250 in.lb Timing Chain Tensioner Arm - Special Pin Bolt 150 in.lb Hydraulic Tensioner Bolts 250 in.lb Timing Chain Primary Tensioner Bolts 250 in.lb Timing Drive Idler Sprocket Bolt 25 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1620 Timing Chain: Testing and Inspection STANDARD PROCEDURE-MEASURING TIMING CHAIN WEAR NOTE: This procedure must be performed with the timing chain cover removed. 1. Remove the timing chain cover.. 2. To determine if the secondary timing chains are worn, rotate the engine clockwise until maximum tensioner piston extension is obtained. Measure the distance between the secondary timing chain tensioner housing and the step ledge on the piston (Fig. 123). The measurement at point (A) must be less than 15 mm (0.5906 inches). 3. If the measurement exceeds the specification the secondary timing chains are worn and require replacement. NOTE: If the secondary chains are to be replaced the primary chain must also be replaced. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1621 Timing Chain: Service and Repair REMOVAL 1. Disconnect negative cable from battery. 2. Drain cooling system. 3. Remove right and left cylinder head covers. 4. Remove radiator fan shroud. 5. Rotate engine until timing mark on crankshaft damper aligns with TDC mark on timing chain cover (# 1 cylinder exhaust stroke) and the camshaft sprocket "V8" marks are at the 12 o'clock position. 6. Remove power steering pump. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1622 7. Remove access plugs (2) from left and right cylinder heads for access to chain guide fasteners. 8. Remove the oil fill housing to gain access to the right side tensioner arm fastener. 9. Remove crankshaft damper and timing chain cover. 10. Collapse and pin primary chain tensioner. CAUTION: Plate behind left secondary chain tensioner could fall into oil pan. Therefore, cover pan opening. 11. Remove secondary chain tensioners. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1623 12. Remove camshaft position sensor from right cylinder head. CAUTION: Care should be taken not to damage camshaft target wheel. Do not hold target wheel while loosening or tightening camshaft sprocket. Do not place the target wheel near a magnetic source of any kind. A damaged or magnetized target wheel could cause a vehicle no start condition. CAUTION: Do not forcefully rotate the camshafts or crankshaft independently of each other. Damaging intake valve to piston contact will occur. Ensure negative battery cable is disconnected to guard against accidental starter engagement. 13. Remove left and right camshaft sprocket bolts. 14. While holding the left camshaft steel tube with adjustable pliers, remove the left camshaft sprocket. Slowly rotate the camshaft approximately 15 degrees clockwise to a neutral position. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1624 15. While holding the right camshaft steel tube with adjustable pliers, remove the right camshaft sprocket. Slowly rotate the camshaft approximately 45 degrees counterclockwise to a neutral position. 16. Remove idler sprocket assembly bolt. 17. Slide the idler sprocket assembly and crank sprocket forward simultaneously to remove the primary and secondary chains. 18. Remove both pivoting tensioner arms and chain guides. 19. Remove chain tensioner. INSPECTION Inspect the following components: Sprockets for excessive tooth wear. Some tooth markings are normal and not a cause for sprocket replacement. - Idler sprocket assembly bushing and shaft for excessive wear. - Idler sprocket assembly spline joint. The joint should be tight with no backlash or axial movement. - Chain guides and tensioner arms. Replace these parts if grooving in plastic face is more than 1 min (0.039 inch) deep. If plastic face is severely grooved or melted, the tensioner lube jet may be clogged. The tensioner should be replaced. - secondary chain tensioner piston and ratcheting device. Inspect for evidence of heavy contact between tensioner piston and tensioner arm. If this condition exist the tensioner and tensioner arm should be replaced. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1625 - Primary chain tensioner plastic faces. Replace as required (Fig. 140). INSTALLATION Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1626 1. Using a vise, lightly compress the secondary chain tensioner piston until the piston step is flush with the tensioner body. Using a pin or suitable tool, release ratchet pawl by pulling pawl back against spring force through access hole on side of tensioner. While continuing to hold pawl back, Push ratchet device to approximately 2 mm from the tensioner body. Install Special Tool 8514 lock pin into hole on front of tensioner. Slowly open vise to transfer piston spring force to lock pin (Fig. 141). 2. Position primary chain tensioner over oil pump and insert bolts into lower two holes on tensioner bracket. Tighten bolts to 28 Nm (250 in. lbs.). CAUTION: Overtightening the tensioner arm torx bolt can cause severe damage to the cylinder head. Tighten torx bolt to specified torque only. 3. Install right side chain tensioner arm. Apply Mopar Lock N Seal to torx bolt, tighten bolt to 17 Nm (150 in. lbs.). NOTE: The silver bolts retain the guides to the cylinder heads and the black bolts retain the guides to the engine block. 4. Install the left side chain guide. Tighten the bolts to 28 Nm (250 in. lbs.). CAUTION: Overtightening the tensioner arm torx@ bolt can cause severe damage to the cylinder head. Tighten torx bolt to specified torque only. 5. Install left side chain tensioner arm. Apply Mopar Lock N, Seal to torx bolt, tighten bolt to 17 Nm (150 in. lbs.). 6. Install the right side chain guide. Tighten the bolts to 28 Nm (250 in. lbs.). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1627 7. Install both secondary chains onto the idler sprocket. Align two plated links on the secondary chains to be visible through the two lower openings on the idler sprocket (4 o'clock and 8 o'clock). Once the secondary timing chains are installed, position special tool 8515 to hold chains in place for installation (Fig. 142). 8. Align primary chain double plated links with the timing mark at 12 o'clock on the idler sprocket. Align the primary chain single plated link with the timing mark at 6 o'clock on the crankshaft sprocket. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1628 9. Lubricate idler shaft and bushings with clean engine oil. 10. Install all chains, crankshaft sprocket, and idler sprocket as an assembly. After guiding both secondary chains through the block and cylinder head openings, affix chains with a elastic strap or the equivalent, This will maintain tension on chains to aid in installation. NOTE: It will be necessary to slightly rotate camshafts for sprocket installation. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1629 11. Align left camshaft sprocket "L" dot to plated link on chain. 12. Align right camshaft sprocket "R" dot to plated link on chain. CAUTION: Remove excess oil from the camshaft sprocket bolt. Failure to do so can result in overtorque of bolt resulting in bolt failure. 13. Remove Special Tool 8515, then attach both sprockets to camshafts. Remove excess oil from bolts, then Install sprocket bolts, but do not tighten at this time. 14. Verify that all plated links are aligned with the marks on all sprockets and the "V8" marks on camshaft sprockets are at the 12 o'clock position. CAUTION: Ensure the plate between the left secondary chain tensioner and block is correctly installed. 15. Install both secondary chain tensioners. Tighten bolts to 28 Nm (250 in. lbs.). NOTE: Left and right secondary chain tensioners are not common. 16. Before installing idler sprocket bolt, lubricate washer with oil, and tighten idler sprocket assembly retaining bolt to 34 Nm (25 ft. lbs.). 17. Remove all locking pins (3) from tensioners. CAUTION: After pulling locking pins out of each tensioner, DO NOT manually extend the tensioner(s) ratchet. Doing so will over tension the chains, resulting in noise and/or high timing chain loads. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1630 18. Using Special Tool 6958, Spanner with Adaptor Pins 8346, tighten left and right (Fig. 145). camshaft sprocket bolts to 122 Nm (90 ft. lbs.). 19. Rotate engine two full revolutions. Verify timing marks are at the follow locations: - primary chain idler sprocket dot is at 12 o'clock - primary chain crankshaft sprocket dot is at 6 o'clock - secondary chain camshaft sprockets "W" marks are at 12 o'clock Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1631 20. Lubricate all three chains with engine oil. 21. After installing all chains, it is recommended that the idler gear end play be checked. The end play must be within 0.10 - 0.25 mm (0.0040 - 0.010 inch). If not within specification, the idler gear must be replaced. 22. Install timing chain cover and crankshaft damper. 23. Install cylinder head covers. NOTE: Before installing threaded )lug in right cylinder head, the plug must be coati id with sealant to prevent leaks. 24. Coat the large threaded access plug with Mopar Thread Sealant with Teflon, then install into the right cylinder head and tighten to 81 Nm (60 ft. lbs.). 25. Install the oil fill housing. 26. Install access plug in left cylinder head. 27. Install power steering pump. 28. Install radiator fan shroud. 29. Fill cooling system. 30. Connect negative cable to battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Guide > Component Information > Specifications Timing Chain Guide: Specifications Timing Chain Guide Bolts 250 in.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications Timing Chain Tensioner: Specifications Timing Chain Tensioner Arm - Special Pin Bolt 150 in.lb Hydraulic Tensioner Bolts 250 in.lb Timing Chain Primary Tensioner Bolts 250 in.lb Timing Drive Idler Sprocket Bolt 25 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Component Alignment Marks > Component Information > Locations Timing Component Alignment Marks: Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Component Alignment Marks > Component Information > Locations > Page 1641 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Timing Chain Cover Bolts 40 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1645 Timing Cover: Service and Repair REMOVAL 1. Disconnect the battery negative cable. 2. Drain cooling system. 3. Remove fan and fan drive assembly. 4. Disconnect both heater hoses at timing cover. 5. Disconnect lower radiator hose at engine. 6. Remove crankshaft damper. 7. Remove accessory drive belt tensioner assembly (Fig. 130). 8. Remove the generator. 9. Remove A/C compressor. 10. Remove cover and gasket (Fig. 131). INSTALLATION 1. Clean timing chain cover and block surface. Inspect cover gasket and replace as necessary. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1646 2. Install cover and gasket. Tighten fasteners in sequence as shown in (Fig. 132) to 54 Nm (40 ft. lbs.). 3. Install the A/C compressor. 4. Install the generator. 5. Install crankshaft damper. 6. Install accessory drive belt tensioner assembly. 7. Install radiator lower hose. 8. Install both heater hoses. 9. Install radiator shroud and viscous fan drive assembly. 10. Fill cooling system. 11. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL Housing removal is not necessary for element (filter) replacement. 1. Pry up spring clips from housing cover (spring clips retain cover to housing). 2. Release housing cover from locating tabs on housing (Fig. 11) and remove cover. 3. Remove air cleaner element (filter) from housing. 4. Clean inside of housing before replacing element. INSTALLATION 1. Install element into housing. 2. Position housing cover into housing locating tabs. 3. Pry up spring clips and lock cover to housing. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions 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 °C (1000 °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. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1663 Fuel Pressure Release: Service and Repair Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator Clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications ENGINE FIRING ORDER - 4.7L V-8 4.7L ENGINE DESCRIPTION Fig. 1 The 4.7 liter (287 CID) eight-cylinder engine is an 90° single overhead camshaft engine. The cast iron cylinder block is made up of two different components; the first component is the cylinder bore and upper block, the second component is the bedplate that comprises the lower portion of the cylinder block and houses the lower half of the crankshaft main bearings. The cylinders are numbered from front to rear with the left bank being numbered 1,3,5 and 7, and the right bank being numbered 2,4,6 and 8. The firing order is 1-8-4-3-6-5-7-2. The engine serial number is located at the Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 1668 right front side of the engine block (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 1669 Firing Order - 4.7L V-8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Firing Order - 4.7L V-8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Specifications Distributor: Specifications Distributor Holddown Bolt .................................................................................................................... .................................................. 23 Nm (17 Ft. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Specifications > Page 1677 Distributor: Service Precautions WARNING: WHEN PERFORMING THE FOLLOWING TEST, THE ENGINE WILL BE RUNNING. BE CAREFUL NOT TO STAND IN LINE WITH THE FAN BLADES OR FAN BELT. DO NOT WEAR LOOSE CLOTHING. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Plug Gap .............................................................................................................................................. .................................................... 1.01 mm (0.040 in.) Tightening Torque ............................................................................................................................... ...................................................... 27 Nm (20 ft. lbs.) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1681 Spark Plug: Locations The spark plug is located under each ignition coil. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1682 Spark Plug: Application and ID Plug Type ............................................................................................................................................ ............................................................... RC12MCC4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1683 Spark Plug: Description and Operation This engine are equipped with "fired in suppressor seal" type spark plugs using a copper core ground electrode. Because of the use of an aluminum cylinder head on this engine, spark plug torque is very critical. To prevent possible pre-ignition and/or mechanical engine damage, the correct type/heat range/number spark plug must be used. 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 intervals recommended in Lubrication and Maintenance. Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or oil fouled. Also refer to Spark Plug Conditions. 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1684 Spark Plug: Testing and Inspection SPARK PLUG CONDITIONS Fig. 20 Normal Operation And Cold (Carbon) Fouling Normal Operating 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. On this engine gap growth will not average more than approximately 0.0015 in per 3200 km (2000 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 may be affected by MMT deposits. Cold Fouling/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 cleaner element or repeated short operating times (short trips). 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1685 Fig. 21 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. Fig. 22 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1686 Fig. 23 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 fuses. 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. Fig. 24 Chipped Electrode 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1687 Fig. 25 Preignition Damage 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.) Fig. 26 Spark Plug 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 2000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions can also cause spark plug overheating. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1688 Spark Plug: Service and Repair REMOVAL 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. In this engine: Each individual spark plug is located under each ignition coil. Each individual ignition coil must be removed to gain access to each spark plug. Refer to Ignition Coil Removal/Installation. 1. In this engine: Prior to removing spark plug, spray compressed air around base of ignition coil at cylinder head. This will help prevent foreign material from entering combustion chamber. 2. Remove spark plug from cylinder head using a quality socket with a rubber or foam insert. If equipped with this engine, also check condition of coil O-ring and replace as necessary. 3. Inspect spark plug condition. Refer to Spark Plug Conditions. CLEANING The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean spark plugs. Metallic deposits will remain on spark plug insulator and will cause plug misfire. INSTALLATION CAUTION: This engine is equipped with copper core ground electrode spark plugs. They must be replaced with the same type/number spark plug as the original. If another spark plug is substituted, pre-ignition will result. 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. 1. Start the spark plug into the cylinder head by hand to avoid cross threading. 2. In this engine: Tighten spark plugs to 27 Nm (20 ft. lbs.) torque. 3. In this engine: Before installing coil(s), check condition of coil O-ring and replace as necessary. To aid in coil installation, apply silicone to coil O-ring. 4. In this engine: Install ignition coil(s). Refer to Ignition Coil Removal/Installation. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications CYLINDER COMPRESSION PRESSURE RANGE: Compression Pressure ........................................................................................................................ ............................................................... 140 - 180 psi Maximum Allowable Variance Between Cylinders ....................................................................................................................................................... 25 % Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1692 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Secure the throttle in the wide-open position. 4. Disable the fuel system. 5. Remove the ASD relay. 6. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. 7. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders. 8. Refer to SPECIFICATIONS for the correct engine compression pressures. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Bolts 40 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1699 Water Pump: Description and Operation DESCRIPTION-WATER PUMP A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core. The pump is driven from the engine crankshaft by a single serpentine drive belt. The water pump impeller is pressed onto the rear of a shaft that rotates in bearings pressed into the housing. The housing has two small holes to allow seepage to escape. The water pump seals are lubricated by the antifreeze in the coolant mixture. No additional lubrication is necessary. Both heater hoses are connected to fittings on the timing chain front cover. The water pump is also mounted directly to the timing chain cover and is equipped with a non serviceable integral pulley. DESCRIPTION-WATER PUMP BYPASS Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1700 The 4.7L engine uses an internal water/coolant bypass system. The design uses galleries in the timing chain cover to circulate coolant during engine warm-up preventing the coolant from flowing through the radiator. The thermostat uses a stub shaft located at the rear of the thermostat to control flow through the bypass gallery. OPERATION-WATER PUMP A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core, this coolant absorbs the heat generated when the engine is running. The pump is driven by the engine crankshaft via a drive belt. OPERATION-WATER PUMP BYPASS When the thermostat is in the closed position the bypass gallery is not obstructed allowing 100% flow. When the thermostat is in the open position the stub shaft enters the bypass gallery obstructing bypass coolant flow by 50%. This design allows the coolant to reach operating temperature quickly when cold, while adding extra cooling during normal temperature operation. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Water Pump Water Pump: Service and Repair Water Pump REMOVAL The water pump on 4.7L engines is bolted directly to the engine timing chain case cover. 1. Disconnect negative battery cable from battery. 2. Drain cooling system. 3. Remove fan/viscous fan drive assembly from water pump. Do not attempt to remove fan/viscous fan drive assembly from vehicle at this time. WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER 6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS. CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter. 4. If water pump is being replaced, do not unbolt fan blade assembly from thermal viscous fan drive. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Water Pump > Page 1703 5. Remove two fan shroud-to-radiator screws. Disconnect the coolant overflow hose, windshield washer fluid hose and washer pump electrical connector. 6. Remove upper fan shroud and fan blade/viscous fan drive assembly from vehicle. 7. After removing fan blade/viscous fan drive assembly, do not place thermal viscous fan drive in horizontal position. If stored horizontally, silicone fluid in viscous fan drive could drain into its bearing assembly and contaminate lubricant. 8. Remove accessory drive belt. 9. Remove lower radiator hose clamp and remove lower hose at water pump. 10. Remove seven water pump mounting bolts and one stud bolt. CAUTION: Do not pry water pump at timing chain case/cover. The machined surfaces may be damaged resulting in leaks. 11. Remove water pump and gasket. Discard gasket. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Water Pump > Page 1704 INSTALLATION The water pump on 4.7L engines is bolted directly to the engine timing chain case cover. 1. Clean gasket mating surfaces. 2. Using a new gasket, position water pump and install mounting bolts as shown. Tighten water pump mounting bolts to 54 Nm (40 ft. lbs.) torque. 3. Spin water pump to be sure that pump impeller does not rub against timing chain case/cover. 4. Connect radiator lower hose to water pump. 5. Relax tension from belt tensioner. Install drive belt. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Water Pump > Page 1705 CAUTION: When installing the serpentine accessory drive belt, belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. Refer to figure for correct belt routing. Or, refer to the Belt Routing Label located in the engine compartment. The correct belt with correct length must be used. 6. Position upper fan shroud and fan blade/viscous fan drive assembly. 7. Be sure the upper and lower portions of the fan shroud are firmly connected. All air must flow through the radiator. 8. Install two fan shroud-to-radiator screws. 9. Be sure of at least 25 mm (1.0 inches) between tips of fan blades and fan shroud. 10. Install fan blade/viscous fan drive assembly to water pump shaft. 11. Fill cooling system. 12. Connect negative battery cable. 13. Start and warm the engine. Check for leaks. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Water Pump > Page 1706 Water Pump: Service and Repair Cleaning and Inspection CLEANING Clean the gasket mating surface. Use caution not to damage the gasket sealing surface. INSPECTION Inspect the water pump assembly for cracks in the housing, Water leaks from shaft seal, Loose or rough turning bearing or Impeller rubbing either the pump body or timing chain case/cover. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Mechanical Specifications Coolant: Mechanical Specifications Coolant 13.0 qt (US) Nominal refill capacities are shown. A variation may be observed vehicle due to manufacturing tolerances and refill procedures. Capacities shown include vehicles with air conditioning and/or heavy duty cooling system. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Mechanical Specifications > Page 1712 Coolant: Capacity Specifications Coolant Capacity With Out Rear Heat ............................................................................................................................. .......................................... 12.6 Liters ( 13.3 qts ) With Rear Heat ..................................................... ......................................................................................................................... 13.4 Liters ( 14.1 qts ) Note: Includes 0.9 Liters ( 1.0 qts ) for coolant reservoir. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Mechanical Specifications > Page 1713 Coolant: Fluid Type Specifications This vehicle has been factory filled with an Ethylene Glycol based engine coolant with long life corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology). When it becomes necessary to replace the coolant, Use a coolant like Mopar Antifreeze/Coolant, 5 year/100,000 mile formula (MS-9769), P/N 5011764AB or equivalent. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 1714 Coolant: Service Precautions DO NOT mix green colored coolant with orange colored coolant. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Description and Operation Coolant Reservoir: Description and Operation DESCRIPTION The coolant recovery container is integral to the upper fan shroud assembly and is made of high temperature plastic. OPERATION The coolant recovery container works in conjunction with the radiator pressure cap. It utilizes thermal expansion and contraction of coolant to keep coolant free of trapped air. It provides a volume for expansion and contraction of coolant. It also provides a convenient and safe method for checking coolant level and adjusting level at atmospheric pressure. This is done without removing the radiator pressure cap. The system also provides some reserve coolant to the radiator to cover minor leaks and evaporation or boiling losses. As the engine cools, a vacuum is formed in the cooling system of both the radiator and engine. Coolant will then be drawn from the coolant tank and returned to a proper level in the radiator. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1723 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1724 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1725 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1726 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1727 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1728 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1729 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1730 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1731 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1732 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1733 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1734 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1735 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1736 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1737 Radiator Cooling Fan Motor: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1738 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1739 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1740 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1741 Radiator Fan Motor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1742 Radiator Cooling Fan Motor: Electrical Diagrams Radiator Fan Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1743 Radiator Fan Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1744 Power Distribution 32 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1745 Fuel/Ignition System 23 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1746 Junction Block 9 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1747 Power Distribution 14 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1748 Power Distribution 32 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 1749 Radiator Cooling Fan Motor: Description and Operation DESCRIPTION The fan is electrically controlled by the powertrain control module (PCM) through the fan control relay. This relay is located in the power distribution center (PDC). For the location of the relay within the PDC, refer to label on PDC cover. OPERATION The PCM regulates fan operation based on input from the engine coolant temperature sensor and vehicle speed. The fan is not energized during engine cranking regardless of the electrical input from the engine coolant temperature sensor. However, if engine operating conditions warrant fan engagement, the fan will run once engine starts. The fan is energized whenever the engine is running and engine coolant or transmission oil sump temperature is greater than 104°C (220°F) or air conditioning head pressure is greater than 32 kPa (220 psi). The fan will turn off when engine coolant or transmission oil sump temperature drops below 102°C (216°F), or air conditioning head pressure drops to 24.6 kPa (170 psi). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 1750 Radiator Cooling Fan Motor: Testing and Inspection The powertrain control module (PCM) will set a diagnostic trouble code (DTC) in memory if it detects a problem in the electric cooling fan, relay or circuit. Refer to On-Board Diagnostics for more information on accessing a DTC. The DTC can also be accessed through the DRB scan tool. Refer to the appropriate Powertrain Diagnostic information for diagnostic information and operation of the DRB scan tool. RADIATOR FAN MOTOR INOPERATIVE Equipment Required. ^ DRB Scan Tool ^ Volt/Ohm meter ^ Wiring Diagrams Test Procedure: 1. Inspect 10A fuse in junction block and 40A maxi fuse in PDC. 2. Remove Cooling Fan Relay from the PDC and make the following checks at the relay connector: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 1751 ^ Apply 12 volts (using a fused 14-gauge wire) to circuit C25 (relay terminal 87). If fan does not come on, check for open in circuit C25 or Z1. If circuits are O.k., replace the cooling fan motor. ^ With the ignition key "off' check for battery voltage at circuit C28 (relay terminal 30). If no battery voltage present check for open/shorted circuit C28 between the PDC and relay. ^ With the ignition key in the "run" position check for battery voltage at circuit F18 (relay terminal 86). If no battery voltage present, check for open/short in circuit F18 between the junction block and the relay. ^ If no problems are detected, install the DRB and start the engine. Clip a 12V test light to the battery positive terminal and probe circuit C27 (relay terminal 85). When the engine temperature reaches 110°C (230°F), or A/C is requested, the test light should light. If not, check circuit C27 for open. ^ If no problems are detected at this point, replace the cooling fan relay. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 1752 Radiator Cooling Fan Motor: Service and Repair REMOVAL If the fan blade is bent, warped, cracked or damaged in any way, it must be replaced only with a replacement fan blade. Do not attempt to repair a damaged fan blade. 1. Disconnect battery negative cable. 2. Disconnect fan motor wire connector. 3. Remove the two fan shroud mounting clips connecting the upper part of fan shroud to the radiator. 4. Remove fan assembly from radiator. INSTALLATION 1. Install fan assembly onto the radiator. Tighten bolts 5 Nm (45 inch lbs.). 2. Connect fan motor wire connector to harness connector. 3. Connect battery negative cable. 4. Start engine and check fan operation. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Power Distribution Center Radiator Fan Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1756 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1757 Radiator Cooling Fan Motor Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1758 Radiator Fan Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1759 Radiator Cooling Fan Motor Relay: Description and Operation DESCRIPTION The radiator cooling fan relay is a 5-pin, solenoid type, mini-relay. It is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. OPERATION The electric radiator cooling fan is controlled by the Powertrain Control Module (PCM) through the radiator cooling fan relay. The PCM will activate the relay after receiving inputs from the engine coolant temperature sensor and/or an air conditioning on/off signal. Not Equipped With A/C: The relay is energized when coolant temperature is above approximately 103°C (217°F). It will then de-energize when coolant temperature drops to approximately 98°C (208°F). Equipped With A/C: In addition to using coolant temperatures to control cooling fan operation, the cooling fan will also be engaged when the air conditioning system has been activated. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Pump > Component Information > Locations Radiator Cooling Fan Pump: Locations The electric coolant pump is located under the hood on the right inner fender well. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Pump > Component Information > Locations > Page 1763 Radiator Cooling Fan Pump: Description and Operation ELECTRIC COOLANT PUMP The electric coolant pump is used on all vehicles. The pump is located under the hood on the right inner fender well. The pump is controlled by the HVAC controller and is only operational under the following conditions: 1. Vehicle speed below 17 m.p.h. 2. Coolant temperature above 1500 but less than 230 °F. 3. Blower speed setting in any position other than OFF. 4. Temperature heat setting above the halfway setting (60% heat). 5. The pump will turn off at speeds above 30 m.p.h. 6. If the coolant temperature rises above 230 °F. 7. The blower switch is turned to the OFF position. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Pump > Component Information > Locations > Page 1764 Radiator Cooling Fan Pump: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative terminal. 2. Drain the engine coolant. 3. Locate pump on right side rear of inner fender and unplug electrical connector. Fig. 6 Electric Coolant Pump 4. Using spring clamp pliers remove both hose clamps from the electric coolant pump. 5. Using a twisting motion gently remove both hoses from the electric coolant pump. 6. Remove electric coolant pump from bracket by gently pulling pump toward front of vehicle. It is not necessary to remove pumps mounting bracket from vehicle. INSTALLATION 1. Install the electric coolant pump by gently pushing the pump on to the pumps mounting bracket. 2. Using a twisting motion gently push both hoses on to the electric coolant pump. 3. Using spring clamp pliers install the hose clamps and secure the hoses to the pump. 4. Plug the electrical connector to the electric coolant pump. 5. Fill the cooling system. 6. Connect the battery negative terminal to the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Service and Repair Fan Blade: Service and Repair CLEANING Clean the fan blades using a mild soap and water. Do not use an abrasive to clean the blades. INSPECTION WARNING: DO NOT ATTEMPT TO BEND OR STRAIGHTEN FAN BLADES IF FAN IS NOT WITHIN SPECIFICATIONS. CAUTION: If fan blade assembly is replaced because of mechanical damage, water pump and viscous fan drive should also be inspected. These components could have been damaged due to excessive vibration. 1. Remove fan blade assembly from viscous fan drive unit (four bolts). 2. Lay fan on a flat surface with leading edge facing down. With tip of blade touching flat surface, replace fan if clearance between opposite blade and surface is greater than 2.0 mm (0.090 inch). Rocking motion of opposite blades should not exceed 2.0 mm (0.090 inch). Test all blades in this manner. 3. Inspect fan assembly for cracks, bends, loose rivets or broken welds. Replace fan if any damage is found. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications Engine Coolant Temperature (ECT) Sensor: Specifications Engine Coolant Temperature Sensor ....................................................................................................................................................... 11 Nm (96 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1772 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1773 Engine Coolant Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1774 Engine Coolant Temperature (ECT) Sensor: Description and Operation DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: ^ for engine coolant temperature gauge operation through CCD or PCI (J1850) ^ Communications ^ Injector pulse-width ^ Spark-advance curves ^ ASD relay shut-down times ^ Idle Air Control (IAC) motor key-on steps ^ Pulse-width prime-shot during cranking ^ 02 sensor closed loop times ^ Purge solenoid on/off times ^ EGR solenoid on/off times (if equipped) ^ Leak Detection Pump operation (if equipped) ^ Radiator fan relay on/off times (if equipped) ^ Target idle speed Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1775 Engine Coolant Temperature (ECT) Sensor: Service and Repair REMOVAL - 4.7L WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. The ECT sensor is located near the front of the intake manifold. 1. Partially drain cooling system. 2. Disconnect electrical connector from ECT sensor. 3. Remove sensor from intake manifold. INSTALLATION - 4.7L 1. Install sensor. 2. Tighten to 11 Nm (8 ft. lbs.) torque. 3. Connect electrical connector to sensor. 4. Replace any lost engine coolant. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Locations Heater Core: Locations The front heater core is located in the HVAC housing, under the instrument panel. The rear heater core is located in the heater-A/C housing in the right rear inside quarter panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Locations > Page 1779 Heater Core: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Locations > Page 1780 Heater Core: Description and Operation HEATER CORE - FRONT The heater core is located in the HVAC housing, under the instrument panel. It is a heat exchanger made of rows of tubes and fins. The heater core is not repairable and if damaged it must be replaced. Engine coolant is circulated through heater hoses to the heater core at all times. As the coolant flows through the heater core, heat removed from the engine is transferred to the heater core fins and tubes. Air directed through the heater core picks up the heat from the heater core fins. The blend door allows control of the heater output air temperature by controlling how much of the air flowing through the HVAC housing is directed through the heater core. The blower motor speed controls the volume of air flowing through the HVAC housing. The heater core cannot be repaired and, if faulty or damaged, it must be replaced. REAR HEATER CORE The rear heater core is located in the heater-A/C housing in the right rear inside quarter panel. It is a heat exchanger made of rows of tubes and fins. The heater core is not repairable and if damaged it must be replaced. Engine coolant is circulated through heater hoses/tubes to the heater core at all times. As the coolant flows through the heater core, heat removed from the engine is transferred to the heater core fins and tubes. Air directed through the heater core picks up the heat from the heater core fins. The blend air door allows control of the heater output air temperature by controlling how much of the air flowing through the heater-A/C housing is directed through the heater core. The blower motor speed controls the volume of air flowing through the heater-A/C housing. The heater core cannot be repaired and, if faulty or damaged, it must be replaced. Refer to Cooling System for more information on the engine cooling system, the engine coolant and the heater hoses. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Front Heater Core: Service and Repair Front REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Drain to cooling systems. 2. Remove the heater-A/C housing from the vehicle. Refer to: Heating and Air Conditioning, Housing Assembly HVAC, Service and Repair, Front, Front HVAC Unit Removal and Installation, See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair/Removal and Replacement/Front HVAC Housing Removal and Installation 3. Disassemble the HVAC housing to access the heater core. 4. Lift the heater core out of the heater-A/C housing. INSTALLATION 1. Insert the heater core into the bottom of the heater-A/C housing. 2. Reassemble the heater-A/C housing. 3. Install the heater-A/C housing into the vehicle. Refer to: Heating and Air Conditioning, Housing Assembly HVAC, Service and Repair, Front, Front HVAC Unit Removal and Installation, See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair/Removal and Replacement/Front HVAC Housing Removal and Installation 4. Refill the cooling system. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Front > Page 1783 Heater Core: Service and Repair Rear REMOVAL 1. Remove the rear trim cover. 2. Remove the three blend door actuator screws. 3. Remove the blend door actuator and place aside. Refer to: "Air Door: Air Door Actuator-Motor" See: Heating and Air Conditioning/Air Door/Air Door Actuator / Motor 4. Remove the two screws from the heater/evaporator tubes plastic retainer. 5. Remove the heater core from the case. INSTALLATION 1. Install the heater core into the heater-A/C housing. 2. Install the two screws to the heater/evaporator tubes plastic retainer. 3. Install the blend door actuator. Refer to: "Air Door: Air Door Actuator-Motor" See: Heating and Air Conditioning/Air Door/Air Door Actuator / Motor 4. Install the three blend door actuator screws. 5. Install the rear trim cover. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Locations Temperature Gauge: Locations The engine coolant temperature gauge is located in the lower left quadrant of the instrument cluster, below the voltage gauge. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Locations > Page 1788 Temperature Gauge: Description and Operation An engine coolant temperature gauge is standard equipment on all instrument clusters. The engine coolant temperature gauge is located in the lower left quadrant of the instrument cluster, below the voltage gauge. The engine coolant temperature gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from "C" (or Cold) to "H" (or Hot) for all engines. An International Control and Display Symbol icon for "Engine Coolant Temperature" is located on the cluster overlay, in the center of the gauge directly above the hub of the gauge needle. The engine coolant temperature gauge graphics are white against a black field except for a single red graduation at the high end of the gauge scale, making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned ON, the white graphics appear blue-green and the red graphics appear red. The orange gauge needle is internally illuminated. Gauge illumination is provided by replaceable incandescent bulb and bulb holder units located on the instrument cluster electronic circuit board. The engine coolant temperature gauge is serviced as a unit with the instrument cluster. The engine coolant temperature gauge gives an indication to the vehicle operator of the engine coolant temperature. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The engine coolant temperature gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Temperature Message - Each time the cluster receives a message from the PCM indicating the engine coolant temperature is between the low end of normal [about 54 °C (130 °F) and the high end of normal [about 129 °C (264 °F), the gauge needle is moved to the actual temperature position on the gauge scale. - Engine Temperature Low Message - Each time the cluster receives a message from the PCM indicating the engine coolant temperature is below the low end of normal [about 54 °C (130 °F)], the gauge needle is held at the "C" increment at the far left end of the gauge scale. The gauge needle remains at the far left end of the scale until the cluster receives a message from the PCM indicating that the engine temperature is above about 54 °C (130 °F), or until the ignition switch is turned to the OFF position, whichever occurs first. - Engine Temperature High Message - Each time the cluster receives a message from the PCM indicating the engine coolant temperature is above about 122 °C (251 °F), the gauge needle is moved to the appropriate position on the gauge scale, the check gauges indicator is illuminated, and a single chime tone is sounded. The check gauges indicator remains illuminated until the cluster receives a message from the PCM indicating that the engine temperature is below about 119 °C (246 °F), or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the check gauges indicator is cycled OFF and then on again by the appropriate engine temperature messages from the PCM. - Message Failure - If the cluster fails to receive an engine temperature message, it will hold the gauge needle at the last indication until a new message is received, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM continually monitors the engine coolant temperature sensor to determine the engine operating temperature. The PCM then sends the proper engine coolant temperature messages to the instrument cluster. For further diagnosis of the engine coolant temperature gauge or the instrument cluster circuitry that controls the gauge, (Refer to INSTRUMENT CLUSTER DIAGNOSIS AND TESTING). If the instrument cluster turns ON the check gauges indicator due to a high engine temperature gauge reading, it may indicate that the engine or the engine cooling system requires service. For proper diagnosis of the engine coolant temperature sensor, the PCM, the PCI data bus, or the message inputs to the instrument cluster that control the engine coolant temperature gauge, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Application and ID Temperature Warning Lamp/Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Temperature Indicator ......................................................................................................................... ............................................................... PC194 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Description and Operation Radiator: Description and Operation DESCRIPTION The radiator is a aluminum cross-flow design with horizontal tubes through the radiator core and vertical plastic side tanks. OPERATION The radiator supplies sufficient heat transfer using the cooling fins interlaced between the horizontal tubes, in the radiator core to cool the engine and automatic transmission oil (if equipped). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Description and Operation > Page 1795 Radiator: Testing and Inspection Use the following procedure to determine if coolant is flowing through cooling system. 1. Idle engine until operating temperature is reached. If upper radiator hose is warm to the touch,thermostat is opening and coolant is flowing to radiator. WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. USING A RAG TO COVER RADIATOR PRESSURE CAP, OPEN RADIATOR CAP SLOWLY TO FIRST STOP ALLOW ANY BUILT-UP PRESSURE TO VENT TO THE RESERVE/ OVERFLOW TANK. AFTER PRESSURE BUILD-UP HAS BEEN RELEASED, REMOVE CAP FROM FILLER NECK. 2. Drain a small amount of coolant from radiator until ends of radiator tubes are visible through filler neck. Idle engine at normal operating temperature. If coolant is flowing past exposed tubes, coolant is circulating. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Removal and Installation Radiator: Service and Repair Removal and Installation REMOVAL WARNING: DO NOT REMOVE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN RADIATOR DRAINCOCK WITH SYSTEM HOT AND UNDER PRESSURE. SERIOUS BURNS FROM COOLANT CAN OCCUR. 1. Disconnect battery negative cable. 2. Drain cooling system. WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER 6094) . SNAP-ON CLAMP TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS. CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter. 3. Remove hose clamps and hoses from radiator. Disconnect coolant reserve/overflow tank hose and washer bottle electrical connector and hose. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Removal and Installation > Page 1798 4. Remove upper fan shroud mounting screws Lift upper fan shroud assembly up and out of engine compartment. 5. Disconnect transmission oil cooler lines, (if equipped). 6. Disconnect electric cooling fan motor connector. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Removal and Installation > Page 1799 7. Remove radiator upper mounting screws. Lift radiator upward and away from vehicle. Do not allow cooling fins of radiator to contact any other vehicle component. Radiator fin damage could result. INSTALLATION The radiator has two isolator pins on bottom of both tanks. These fit into alignment holes in radiator lower support. 1. Position isolator pins into alignment holes in radiator lower support. 2. Install and tighten radiator mounting bolts to 23 Nm (200 inch lbs.). 3. Install the transmission oil cooler lines, (if equipped). 4. Connect fan motor electrical connector to harness connector. 5. Position upper fan shroud onto lower fan shroud and radiator. 6. Install retaining screws into shroud. 7. Install radiator hoses. reconnect coolant reserve/overflow tank hose. 8. Connect battery negative cable. 9. Fill cooling system. 10. Start and warm the engine. Check for leaks. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Removal and Installation > Page 1800 Radiator: Service and Repair Cleaning and Inspection CLEANING Clean radiator fins With the engine cold, apply cold water and compressed air to the back (engine side) of the radiator to flush the radiator and/or A/C condenser of debris. INSPECTION The radiator cooling fins should be checked for damage or deterioration. Inspect cooling fins to make sure they are not bent or crushed, these areas result in reduced heat exchange causing the cooling system to operate at higher temperatures. Inspect the plastic end tanks for cracks, damage or leaks. Inspect the radiator neck for damage or distortion. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Technical Service Bulletins > Radiator Cap - Correct Installation Radiator Cap: Technical Service Bulletins Radiator Cap - Correct Installation NUMBER: 07-001-01 GROUP: Cooling DATE: Feb. 23, 2001 SUBJECT: Radiator Cap Installation MODELS: 2001 (AN) Dakota 2001 (DN) Durango DISCUSSION: The radiator cap can be installed on the filler neck incorrectly when servicing the cooling system. The radiator cap lock tab may ride up on the filler neck radiator cap raised retention lip if the cap is not installed carefully causing the cap to not be fully seated (Fig. 1). A radiator cap that is not fully seated could cause a loss of coolant and reduce the cooling system performance. CAUTION: WHEN INSTALLING THE RADIATOR CAP ON SUBJECT MODEL VEHICLES, MAKE SURE THE CAP IS INSTALLED SO THAT THE RADIATOR CAP LOCKS INTO PLACE BELOW BOTH FILLER NECK RADIATOR CAP RAISED RETENTION LIPS (FIGURE 2). NOTE: DO NOT REMOVE THE RADIATOR CAP FOR ROUTINE COOLANT LEVEL INSPECTIONS. THE COOLANT LEVEL CAN BE CHECKED Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Technical Service Bulletins > Radiator Cap - Correct Installation > Page 1805 AT THE COOLANT RECOVERY BOTTLE. REMOVE THE RECOVERY BOTTLE CAP AND REMOVE THE COOLANT LEVEL INDICATOR DIPSTICK TO OBSERVE THE COOLANT LEVEL IN THE COOLANT RECOVERY BOTTLE. FOR ADDITIONAL INFORMATION, REFER TO THE SERVICE INFORMATION IN THE APPROPRIATE SERVICE MANUAL OR ON THE MDS2, GROUP 07, STANDARD PROCEDURE-COOLANT LEVEL CHECK. POLICY: Information Only Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Technical Service Bulletins > Page 1806 Radiator Cap: Description and Operation DESCRIPTION All cooling systems are equipped with a pressure cap in the radiator upper hose. This cap releases pressure at some point within a range of 131-to-158 kPa (19-to-23 psi). The pressure relief point (in pounds) is engraved on top of the cap The cooling system will operate at pressures slightly above atmospheric pressure. This results in a higher coolant boiling point allowing increased radiator cooling capacity. The cap contains a spring loaded pressure relief valve. This valve opens when system pressure reaches the release range of 131-to158 kPa (19-to-23 psi). A rubber gasket seals the radiator filler neck. This is done to maintain vacuum during coolant cool-down and to prevent leakage when system is under pressure. OPERATION A vent valve in the center of the cap will remain shut as long as the cooling system is pressurized. As the coolant cools, it contracts and creates a vacuum in cooling system. This causes the vacuum valve to open and coolant in reserve/overflow tank to be drawn through connecting hose into radiator. If the vacuum valve is stuck shut, or overflow hose is kinked, radiator hoses will collapse on cool-down. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Cooling System Pressure Relief Testing Radiator Cap: Testing and Inspection Cooling System Pressure Relief Testing RADIATOR CAP-TO-FILLER NECK SEAL The pressure cap upper gasket (seal) pressure relief can be tested by removing overflow hose from radiator filler neck nipple. Attach hose of pressure tester tool 7700 (or equivalent) to nipple. It will be necessary to disconnect hose from its adapter for filler neck. Pump air into radiator. The pressure cap upper gasket should relieve at 131 kPa (21 psi) and hold pressure at a minimum of 130 kPa. (18.8 psi). WARNING: THE WARNING WORDS -DO NOT OPEN HOT- ON RADIATOR PRESSURE CAP, ARE A SAFETY PRECAUTION. WHEN HOT, PRESSURE BUILDS UP IN COOLING SYSTEM. TO PREVENT SCALDING OR INJURY, RADIATOR CAP SHOULD NOT BE REMOVED WHILE SYSTEM IS HOT AND/OR UNDER PRESSURE. Do not remove radiator cap at any time except for the following purposes: 1. Check and adjust antifreeze freeze point. 2. Refill system with new antifreeze. 3. Conducting service procedures. 4. Checking for vacuum leaks. WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, WAIT AT LEAST 15 MINUTES BEFORE REMOVING RADIATOR CAP. WITH A RAG, SQUEEZE RADIATOR UPPER HOSE TO CHECK IF SYSTEM IS UNDER PRESSURE. PLACE A RAG OVER CAP AND WITHOUT PUSHING CAP DOWN, ROTATE IT COUNTERCLOCKWISE TO FIRST STOP. ALLOW FLUID TO ESCAPE THROUGH THE COOLANT RESERVE/ OVERFLOW HOSE INTO RESERVE/OVERFLOW TANK. SQUEEZE RADIATOR UPPER HOSE TO DETERMINE WHEN PRESSURE HAS BEEN RELEASED. WHEN COOLANT AND STEAM STOP BEING PUSHED INTO TANK AND SYSTEM PRESSURE DROPS, REMOVE RADIATOR CAP COMPLETELY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Cooling System Pressure Relief Testing > Page 1809 Radiator Cap: Testing and Inspection Radiator Cap Testing RADIATOR CAP Remove cap from radiator. Be sure that sealing surfaces are clean. Moisten rubber gasket with water and install cap on pressure tester 7700 or an equivalent. Operate tester pump to bring pressure to 138 kPa (20 psi) on gauge. If pressure cap fails to hold pressure of at least 131 kPa (19 psi) replace cap. Refer to following CAUTION. The pressure cap may test properly while positioned on tool 7700 (or equivalent). It may not hold pressure or vacuum when installed on radiator. If so, inspect radiator filler neck and cap's top gasket for damage. Also inspect for dirt or distortion that may prevent cap from sealing properly. CAUTION: Radiator pressure testing tools are very sensitive to small air leaks, which will not cause cooling system problems. A pressure cap that does not have a history of coolant loss should not be replaced just because it leaks slowly when tested with this tool. Add water to tool. Turn tool upside down and recheck pressure cap to confirm that cap needs replacement. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Page 1810 Radiator Cap: Service and Repair CLEANING Use only a mild soap and water to clean the radiator cap. Using any type solvent may cause damage to the seal in the radiator cap. INSPECTION Hold cap at eye level, right side up. The vent valve at bottom of cap should open. If rubber gasket has swollen and prevents vent valve from opening, replace cap. Hold cap at eye level, upside down. If any light can be seen between vent valve and rubber gasket, replace cap. Do not use a replacement cap that has a spring to hold vent shut. A replacement cap must be the type designed for a coolant reserve/overflow system with a completely sealed diaphragm spring and a rubber gasket. This gasket is used to seal to radiator filler neck top surface. Use of proper cap will allow coolant return to radiator. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Power Distribution Center Radiator Fan Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1815 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1816 Radiator Cooling Fan Motor Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1817 Radiator Fan Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1818 Radiator Cooling Fan Motor Relay: Description and Operation DESCRIPTION The radiator cooling fan relay is a 5-pin, solenoid type, mini-relay. It is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. OPERATION The electric radiator cooling fan is controlled by the Powertrain Control Module (PCM) through the radiator cooling fan relay. The PCM will activate the relay after receiving inputs from the engine coolant temperature sensor and/or an air conditioning on/off signal. Not Equipped With A/C: The relay is energized when coolant temperature is above approximately 103°C (217°F). It will then de-energize when coolant temperature drops to approximately 98°C (208°F). Equipped With A/C: In addition to using coolant temperatures to control cooling fan operation, the cooling fan will also be engaged when the air conditioning system has been activated. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications Engine Coolant Temperature (ECT) Sensor: Specifications Engine Coolant Temperature Sensor ....................................................................................................................................................... 11 Nm (96 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1824 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1825 Engine Coolant Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1826 Engine Coolant Temperature (ECT) Sensor: Description and Operation DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: ^ for engine coolant temperature gauge operation through CCD or PCI (J1850) ^ Communications ^ Injector pulse-width ^ Spark-advance curves ^ ASD relay shut-down times ^ Idle Air Control (IAC) motor key-on steps ^ Pulse-width prime-shot during cranking ^ 02 sensor closed loop times ^ Purge solenoid on/off times ^ EGR solenoid on/off times (if equipped) ^ Leak Detection Pump operation (if equipped) ^ Radiator fan relay on/off times (if equipped) ^ Target idle speed Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1827 Engine Coolant Temperature (ECT) Sensor: Service and Repair REMOVAL - 4.7L WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. The ECT sensor is located near the front of the intake manifold. 1. Partially drain cooling system. 2. Disconnect electrical connector from ECT sensor. 3. Remove sensor from intake manifold. INSTALLATION - 4.7L 1. Install sensor. 2. Tighten to 11 Nm (8 ft. lbs.) torque. 3. Connect electrical connector to sensor. 4. Replace any lost engine coolant. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Locations Temperature Gauge: Locations The engine coolant temperature gauge is located in the lower left quadrant of the instrument cluster, below the voltage gauge. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Locations > Page 1831 Temperature Gauge: Description and Operation An engine coolant temperature gauge is standard equipment on all instrument clusters. The engine coolant temperature gauge is located in the lower left quadrant of the instrument cluster, below the voltage gauge. The engine coolant temperature gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from "C" (or Cold) to "H" (or Hot) for all engines. An International Control and Display Symbol icon for "Engine Coolant Temperature" is located on the cluster overlay, in the center of the gauge directly above the hub of the gauge needle. The engine coolant temperature gauge graphics are white against a black field except for a single red graduation at the high end of the gauge scale, making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned ON, the white graphics appear blue-green and the red graphics appear red. The orange gauge needle is internally illuminated. Gauge illumination is provided by replaceable incandescent bulb and bulb holder units located on the instrument cluster electronic circuit board. The engine coolant temperature gauge is serviced as a unit with the instrument cluster. The engine coolant temperature gauge gives an indication to the vehicle operator of the engine coolant temperature. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The engine coolant temperature gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Temperature Message - Each time the cluster receives a message from the PCM indicating the engine coolant temperature is between the low end of normal [about 54 °C (130 °F) and the high end of normal [about 129 °C (264 °F), the gauge needle is moved to the actual temperature position on the gauge scale. - Engine Temperature Low Message - Each time the cluster receives a message from the PCM indicating the engine coolant temperature is below the low end of normal [about 54 °C (130 °F)], the gauge needle is held at the "C" increment at the far left end of the gauge scale. The gauge needle remains at the far left end of the scale until the cluster receives a message from the PCM indicating that the engine temperature is above about 54 °C (130 °F), or until the ignition switch is turned to the OFF position, whichever occurs first. - Engine Temperature High Message - Each time the cluster receives a message from the PCM indicating the engine coolant temperature is above about 122 °C (251 °F), the gauge needle is moved to the appropriate position on the gauge scale, the check gauges indicator is illuminated, and a single chime tone is sounded. The check gauges indicator remains illuminated until the cluster receives a message from the PCM indicating that the engine temperature is below about 119 °C (246 °F), or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the check gauges indicator is cycled OFF and then on again by the appropriate engine temperature messages from the PCM. - Message Failure - If the cluster fails to receive an engine temperature message, it will hold the gauge needle at the last indication until a new message is received, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM continually monitors the engine coolant temperature sensor to determine the engine operating temperature. The PCM then sends the proper engine coolant temperature messages to the instrument cluster. For further diagnosis of the engine coolant temperature gauge or the instrument cluster circuitry that controls the gauge, (Refer to INSTRUMENT CLUSTER DIAGNOSIS AND TESTING). If the instrument cluster turns ON the check gauges indicator due to a high engine temperature gauge reading, it may indicate that the engine or the engine cooling system requires service. For proper diagnosis of the engine coolant temperature sensor, the PCM, the PCI data bus, or the message inputs to the instrument cluster that control the engine coolant temperature gauge, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Application and ID Temperature Warning Lamp/Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Temperature Indicator ......................................................................................................................... ............................................................... PC194 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications Thermostat Starts to Open 195 F Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1838 Thermostat: Description and Operation DESCRIPTION CAUTION: Do not operate an engine without a thermostat, except for servicing or testing. A pellet-type thermostat controls the operating temperature of the engine by controlling the amount of coolant flow to the radiator. On all engines the thermostat is closed below 195°F (90°C). Above this temperature, coolant is allowed to flow to the radiator. This provides quick engine warm up and overall temperature control. On the 4.7L engine the thermostat is designed to block the flow of the coolant bypass journal by 50% instead of completely blocking the flow. This design controls coolant temperature more accurately. The same thermostat is used for winter and summer seasons. An engine should not be operated without a thermostat, except for servicing or testing. Operating without a thermostat causes other problems. These are: longer engine warm-up time, unreliable warm-up performance, increased exhaust emissions and crankcase condensation. This condensation can result in sludge formation. OPERATION The wax pellet is located in a sealed container at the spring end of the thermostat. When heated, the pellet expands, overcoming closing spring tension and water pump pressure to force the valve to open. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1839 Thermostat: Testing and Inspection ON-BOARD DIAGNOSTICS All gasoline powered models are equipped with On-Board Diagnostics for certain cooling system components. Refer to On-Board Diagnostics (OBD) for additional information. If the powertrain control module (PCM) detects low engine coolant temperature, it will record a Diagnostic Trouble Code (DTC) in the PCM memory. Do not change a thermostat for lack of heat as indicated by the instrument panel gauge or by poor heater performance unless a DTC is present. Refer to the Diagnosis for other probable causes. The DTC can also be accessed through the DRB scan tool. Refer to the appropriate Powertrain Diagnostic Procedures information for diagnostic information and operation of the DRB scan tool. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1840 Thermostat: Service and Repair REMOVAL WARNING: DO NOT LOOSEN RADIATOR DRAINCOCK WITH SYSTEM HOT AND PRESSURIZED. SERIOUS BURNS FROM COOLANT CAN OCCUR. Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse. If thermostat is being replaced, be sure that replacement is specified thermostat for vehicle model and engine type. 1. Disconnect negative battery cable at battery. 2. Drain cooling system. 3. Raise vehicle on hoist. 4. Remove splash shield. 5. Remove lower radiator hose clamp and lower radiator hose at thermostat housing. 6. Remove thermostat housing mounting bolts, thermostat housing and thermostat. INSTALLATION 1. Clean mating areas of timing chain cover and thermostat housing. 2. Install thermostat (spring side down) into recessed machined groove on timing chain cover. 3. Position thermostat housing on timing chain cover. 4. Install two housing-to-timing chain cover bolts. Tighten bolts to 13 Nm (112 inch lbs.) torque. CAUTION: Housing must be tightened evenly and thermostat must be centered into recessed groove in timing chain cover. If not, it may result in a cracked housing, damaged timing chain cover threads or coolant leaks. 5. Install lower radiator hose on thermostat housing. 6. Install splash shield. 7. Lower vehicle. 8. Fill cooling system. 9. Connect negative battery cable to battery. 10. Start and warm the engine. Check for leaks. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications Thermostat Housing: Specifications Thermostat Housing Bolts 115 in.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications > Page 1844 Thermostat Housing: Service and Repair REMOVAL WITHOUT AIR CONDITIONING 1. Partially drain cooling system. Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse. WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER 6094) . SNAP-ON CLAMP TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS. CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter. 2. Loosen both bypass hose clamps and position to center of hose. Remove hose from vehicle. WITH AIR CONDITIONING Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications > Page 1845 If equipped with A/C, the generator and A/C compressor along with their common mounting bracket must be partially removed. Removing generator or A/C compressor from their mounting bracket is not necessary. Also, discharging A/C system is not necessary. Do not remove any refrigerant lines from A/C compressor. WARNING: THE A/C SYSTEM IS UNDER PRESSURE EVEN WITH ENGINE OFF. REFER TO REFRIGERANT WARNINGS. 1. Disconnect battery negative cable. 2. Partially drain cooling system. Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse. 3. Remove upper radiator hose clamp and hose at radiator. 4. Unplug wiring harness from A/C compressor. 5. Remove air cleaner assembly. 6. Remove accessory drive belt. 7. The drive belt idler pulley must be removed to gain access to one of A/C compressor/generator bracket mounting bolts. Remove idler pulley bolt and remove idler pulley. 8. Remove oil dipstick tube mounting bolt at side of A/C-generator mounting bracket. 9. Disconnect throttle body cables. 10. Remove heater hose clamp and heater hose from heater hose coolant return tube. 11. Remove heater hose coolant return tube mounting bolt and remove tube from engine. Discard the old tube O-ring. 12. Remove bracket-to-intake manifold bolts . Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications > Page 1846 13. Remove six bracket bolts. 14. Lift and position generator and A/C compressor (along with their common mounting bracket) to gain access to bypass hose. A block of wood may be used to hold assembly in position. 15. Loosen and position both hose clamps to center of bypass hose. Remove hose from vehicle. INSTALLATION WITHOUT AIR CONDITIONING 1. Position bypass hose clamps to center of hose. 2. Install bypass hose to engine. 3. Secure both hose clamps. 4. Fill cooling system. 5. Start and warm the engine. Check for leaks. WITH AIR CONDITIONING 1. Position bypass hose clamps to center of hose. 2. Install bypass hose to engine. 3. Secure both hose clamps . 4. Install generator-A/C mounting bracket assembly to engine. Tighten bolts (number 1 and 2- to 54 Nm (40 ft. lbs.) torque. Tighten bolts (number 3- to 40 Nm (30 ft. lbs.) torque. 5. Install a new 0-ring to the heater hose coolant return tube . Coat the new O-ring with antifreeze before installation. 6. Install coolant return tube and its mounting bolt to engine. 7. Connect throttle body control cables. 8. Install oil dipstick mounting bolt. 9. Install idler pulley. Tighten bolt to 54 Nm (40 ft. lbs.) torque. 10. Install drive belt. 11. Install air cleaner assembly. 12. Install upper radiator hose to radiator. 13. Connect wiring harness to A/C compressor. 14. Connect battery negative cable. 15. Fill cooling system. 16. Start and warm the engine. Check for leaks. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Bolts 40 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1850 Water Pump: Description and Operation DESCRIPTION-WATER PUMP A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core. The pump is driven from the engine crankshaft by a single serpentine drive belt. The water pump impeller is pressed onto the rear of a shaft that rotates in bearings pressed into the housing. The housing has two small holes to allow seepage to escape. The water pump seals are lubricated by the antifreeze in the coolant mixture. No additional lubrication is necessary. Both heater hoses are connected to fittings on the timing chain front cover. The water pump is also mounted directly to the timing chain cover and is equipped with a non serviceable integral pulley. DESCRIPTION-WATER PUMP BYPASS Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1851 The 4.7L engine uses an internal water/coolant bypass system. The design uses galleries in the timing chain cover to circulate coolant during engine warm-up preventing the coolant from flowing through the radiator. The thermostat uses a stub shaft located at the rear of the thermostat to control flow through the bypass gallery. OPERATION-WATER PUMP A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core, this coolant absorbs the heat generated when the engine is running. The pump is driven by the engine crankshaft via a drive belt. OPERATION-WATER PUMP BYPASS When the thermostat is in the closed position the bypass gallery is not obstructed allowing 100% flow. When the thermostat is in the open position the stub shaft enters the bypass gallery obstructing bypass coolant flow by 50%. This design allows the coolant to reach operating temperature quickly when cold, while adding extra cooling during normal temperature operation. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Water Pump Water Pump: Service and Repair Water Pump REMOVAL The water pump on 4.7L engines is bolted directly to the engine timing chain case cover. 1. Disconnect negative battery cable from battery. 2. Drain cooling system. 3. Remove fan/viscous fan drive assembly from water pump. Do not attempt to remove fan/viscous fan drive assembly from vehicle at this time. WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER 6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS. CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter. 4. If water pump is being replaced, do not unbolt fan blade assembly from thermal viscous fan drive. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Water Pump > Page 1854 5. Remove two fan shroud-to-radiator screws. Disconnect the coolant overflow hose, windshield washer fluid hose and washer pump electrical connector. 6. Remove upper fan shroud and fan blade/viscous fan drive assembly from vehicle. 7. After removing fan blade/viscous fan drive assembly, do not place thermal viscous fan drive in horizontal position. If stored horizontally, silicone fluid in viscous fan drive could drain into its bearing assembly and contaminate lubricant. 8. Remove accessory drive belt. 9. Remove lower radiator hose clamp and remove lower hose at water pump. 10. Remove seven water pump mounting bolts and one stud bolt. CAUTION: Do not pry water pump at timing chain case/cover. The machined surfaces may be damaged resulting in leaks. 11. Remove water pump and gasket. Discard gasket. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Water Pump > Page 1855 INSTALLATION The water pump on 4.7L engines is bolted directly to the engine timing chain case cover. 1. Clean gasket mating surfaces. 2. Using a new gasket, position water pump and install mounting bolts as shown. Tighten water pump mounting bolts to 54 Nm (40 ft. lbs.) torque. 3. Spin water pump to be sure that pump impeller does not rub against timing chain case/cover. 4. Connect radiator lower hose to water pump. 5. Relax tension from belt tensioner. Install drive belt. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Water Pump > Page 1856 CAUTION: When installing the serpentine accessory drive belt, belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. Refer to figure for correct belt routing. Or, refer to the Belt Routing Label located in the engine compartment. The correct belt with correct length must be used. 6. Position upper fan shroud and fan blade/viscous fan drive assembly. 7. Be sure the upper and lower portions of the fan shroud are firmly connected. All air must flow through the radiator. 8. Install two fan shroud-to-radiator screws. 9. Be sure of at least 25 mm (1.0 inches) between tips of fan blades and fan shroud. 10. Install fan blade/viscous fan drive assembly to water pump shaft. 11. Fill cooling system. 12. Connect negative battery cable. 13. Start and warm the engine. Check for leaks. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Water Pump > Page 1857 Water Pump: Service and Repair Cleaning and Inspection CLEANING Clean the gasket mating surface. Use caution not to damage the gasket sealing surface. INSPECTION Inspect the water pump assembly for cracks in the housing, Water leaks from shaft seal, Loose or rough turning bearing or Impeller rubbing either the pump body or timing chain case/cover. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation Catalytic Converter: Description and Operation DESCRIPTION California emissions vehicles incorporate mini catalytic converters into the exhaust system. These catalytic converters are made of stainless steel designed to operate at extremely high temperatures. OPERATION The catalytic converter captures and bums any unburned fuel mixture exiting the combustion chambers during the exhaust stroke of the engine. This process aids in reducing emissions output. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 1862 Catalytic Converter: Service and Repair REMOVAL The mini catalytic converters used on the 4.7L engine is an integral part of the exhaust pipe. To replace the mini catalytic converters, the entire exhaust pipe assembly must be replaced. CAUTION: When servicing or replacing exhaust system components, disconnect the oxygen sensor connector(s). Allowing the exhaust to hang by the oxygen sensor wires will damage the harness and/or sensor. 1. Raise and support the vehicle. 2. Saturate the bolts and nuts with Mopar Rust Penetrant. Allow 5 minutes for penetration. 3. Remove the clamp holding the catalytic converter flange to the exhaust pipe(s). 4. Remove the clamp holding the catalytic converter flange to the muffler or extension pipe . 5. Remove the engine rear mount. 6. Remove the crossmember. 7. Remove the catalytic converter. You may have to loosen up other sections of the exhaust system. INSPECTION Look at the stainless steel body of the converter, inspect for bulging or other distortion that could be a result of overheating. If the converter has a heat shield attached make sure it is not bent or loose. If you suspect internal damage to the catalyst, tapping the bottom of the catalyst with a rubber mallet may indicate a damaged core. INSTALLATION CAUTION: When servicing or replacing exhaust system components, disconnect the oxygen sensor connector(s). Allowing the exhaust to hang by the oxygen sensor wires will damage the harness and/or sensor. 1. Align and connect the catalytic converter flange to the exhaust pipe. 2. Install the catalytic converter flange into the muffler or extension pipe. 3. If other sections of the exhaust system where loosened in removal, refer to tightening procedures. 4. At the catalytic converter flange connections, install the clamp and nuts. Tighten the clamp nuts to 41 Nm (30 ft. lbs.) torque. 5. Install the crossmember. 6. Install the rear engine mount. 7. Lower the vehicle. 8. Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels. Adjust the alignment, if needed. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust Manifold Bolts 18 ft.lb Tighten all manifold bolts starting at center and working outward. Exhaust Manifold Heat Shield Nuts 72 in.lb Then loosen 45 degrees Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 1866 Exhaust Manifold: Description and Operation DESCRIPTION The exhaust manifolds are log style with a patented flow enhancing design to maximize performance. The exhaust manifolds are made of high silicon molybdenum cast iron. A perforated core graphite exhaust manifold gasket is used to improve sealing to the cylinder head. The exhaust manifolds are covered by a three layer laminated heat shield for thermal protection and noise reduction. The heat shields are fastened with a torque prevailing nut that is backed off slightly to allow for the thermal expansion of the exhaust manifold. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Removal and Installation Exhaust Manifold: Service and Repair Removal and Installation REMOVAL RIGHT EXHAUST MANIFOLD 1. Disconnect negative cable for battery. 2. Remove air cleaner assembly, resonator assembly and air inlet hose. 3. Remove accessory drive belt. 4. Remove A/C compressor. 5. Remove A/C accumulator support bracket fastener. 6. Drain coolant below heater hose level. 7. Remove heater hoses at engine. 8. Remove fasteners attaching exhaust manifold heat shield. 9. Remove heat shield. 10. Remove upper exhaust manifold attaching fasteners. 11. Raise vehicle on hoist. 12. Disconnect exhaust pipe from manifold. 13. Remove fasteners attaching starter. Move starter aside. 14. Remove lower exhaust manifold attaching fasteners. 15. Remove exhaust manifold and gasket. Manifold is removed from below the engine compartment. LEFT EXHAUST MANIFOLD 1. Disconnect negative cable for battery. 2. Hoist vehicle. 3. Disconnect exhaust pipe at manifold. 4. Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Removal and Installation > Page 1869 5. Remove the front two exhaust heat shield retaining fasteners. Raise vehicle and remove the fasteners at rear of heat shield. 6. Remove heat shield. 7. Lower vehicle and remove the upper exhaust manifold retaining bolts. 8. Raise vehicle and remove the lower exhaust manifold retaining bolts. 9. Remove exhaust manifold and gasket. Manifold is removed from below the engine compartment. INSTALLATION RIGHT EXHAUST MANIFOLD Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Removal and Installation > Page 1870 1. Install exhaust manifold and gasket from below engine compartment. 2. Install lower exhaust manifold fasteners. DO NOT tighten until all fasteners are in place. 3. Lower vehicle and install upper exhaust manifold fasteners. Tighten all manifold bolts starting at center and working outward to 25 Nm (18 ft. lbs.). CAUTION: Over tightening heat shield fasteners, may cause shield to distort and/or crack. 4. Install exhaust manifold heat shield. Tighten fasteners to 8 Nm (72 inch lbs.), then loosen 45 degrees. 5. Install starter and fasteners. 6. Connect exhaust pipe to manifold. 7. Connect heater hoses at engine. 8. Install fastener attaching A/C accumulator. 9. Install A/C compressor and fasteners. 10. Install accessory drive belt. 11. Install air cleaner assembly, resonator assembly and air inlet hose. 12. Install battery and connect cables. 13. Fill cooling system. LEFT EXHAUST MANIFOLD 1. Install exhaust manifold and gasket from below engine compartment. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Removal and Installation > Page 1871 2. Install lower exhaust manifold fasteners. DO NOT tighten until all fasteners are in place. 3. Lower vehicle and install upper exhaust manifold fasteners. Tighten all manifold bolts starting at center and working outward to 25 Nm (18 ft. lbs.). CAUTION: Over tightening heat shield fasteners, may cause shield to distort and/or crack. 4. Install exhaust manifold heat shield. Tighten fasteners to 8 Nm (72 inch lbs.), then loosen 45 degrees. 5. Connect exhaust pipe to manifold. 6. Connect negative cable to battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Removal and Installation > Page 1872 Exhaust Manifold: Service and Repair Cleaning and Inspection CLEANING 1. Clean the exhaust manifold using a suitable cleaning solvent, then allow to air dry. 2. Clean all gasket residue from the manifold mating surface. INSPECTION 1. Inspect the exhaust manifold for cracks in the mating surface and at every mounting bolt hole. 2. Using a straight edge and a feeler gauge, check the mating surface for warp and twist. 3. Inspect the manifold to exhaust pipe mating surface for cracks, gouges, or other damage that would prevent sealing. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Description and Operation Exhaust Pipe: Description and Operation DESCRIPTION The tailpipe is made of stainless steel and attaches to the muffler. OPERATION The tailpipe channels the exhaust out of the muffler and out from under the vehicle to control noise and prevent exhaust gas fumes from entering the passenger compartment. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe Exhaust Pipe: Service and Repair Exhaust Pipe REMOVAL CAUTION: When servicing or replacing exhaust system components, disconnect the oxygen sensor connector(s). Allowing the exhaust to hang by the oxygen sensor wires will damage the harness and/or sensor. 1. Raise and support the vehicle. 2. Saturate the bolts and nuts with Mopar Rust Penetrant. Allow 5 minutes for penetration. 3. Disconnect the oxygen sensor(s). 4. Remove the exhaust manifold-to-exhaust pipe nuts. 5. Remove exhaust pipe to converter exhaust clamp. 6. Disconnect the exhaust pipe from the catalytic converter front flange. 7. Remove the exhaust pipe. INSPECTION Discard rusted clamps, broken or worn supports and attaching parts. Replace a component with original equipment parts, or equivalent. This will assure proper alignment with other parts in the system and provide acceptable exhaust noise levels. INSTALLATION 1. Connect the exhaust pipe(s) to the exhaust manifold. Tighten the nuts to 26 Nm (19 ft. lbs.) torque. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe > Page 1878 2. Align and connect the exhaust pipe to the catalytic converter flange. Install exhaust clamp and tighten clamp nuts to 41 Nm (33 ft. lbs.) torque. 3. Connect oxygen sensor connector(s). 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe > Page 1879 Exhaust Pipe: Service and Repair Tailpipe REMOVAL WARNING: IF TORCHES ARE USED WHEN WORKING ON THE EXHAUST SYSTEM, WEAR PROTECTIVE EYE COVERING AND DO NOT ALLOW THE FLAME NEAR THE FUEL LINES. CAUTION: When servicing or replacing exhaust system components, be sure to disconnect all oxygen sensor connectors. Allowing the exhaust system to hang by the harness will damage the wiring and/or sensor. 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Disconnect tailpipe from rear hanger bracket. 4. Remove muffler to tailpipe exhaust clamp. 5. Heat connection with an oxygen/acetylene torch and twist tailpipe out of muffler. INSTALLATION 1. Install tailpipe to muffler. Install exhaust clamp and start nuts by hand. 2. Connect tailpipe hanger. 3. Align tailpipe and tighten exhaust clamp nuts to 42 Nm (31 ft. lbs.). 4. Lower vehicle and connect battery negative cable. 5. Start engine and check for exhaust leaks. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 11-002-01 > Sep > 01 > Evaporator Drain/Exhaust - Hissing Sound Heat Shield: Customer Interest Evaporator Drain/Exhaust - Hissing Sound NUMBER: 11-002-01 GROUP: Exhaust DATE: Sept. 14, 2001 SUBJECT: Hissing Sound When Water From The Evaporator Drain Drips On Exhaust OVERVIEW: This bulletin involves installing a revised exhaust system heat shield containing a drain trough to route water away from the exhaust system. MODELS: 2001 (AN) Dakota 2001 (DN) Durango SYMPTOM/CONDITION: A hissing sound may be present when water from the A/C evaporator drain drips onto the exhaust system. DIAGNOSIS: If the condition is present or the customer indicates that the vehicle exhibits the condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. WARNING: THE ENGINE AND EXHAUST SYSTEM MAY BE EXTREMELY HOT. ALLOW SUFFICIENT TIME FOR THE ENGINE AND EXHAUST SYSTEM TO COOL PRIOR TO PERFORMING THIS PROCEDURE. 1. Locate the heat shield in the engine compartment directly above the right side exhaust manifold to front exhaust pipe connection. 2. Remove the two screws attaching the heat shield to the bulkhead and remove the shield. Discard the shield. 3. Install the new shield, P/N 55257336AB, with the drain trough located at the top. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 11-002-01 > Sep > 01 > Evaporator Drain/Exhaust - Hissing Sound > Page 1888 FAILURE CODE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 11-002-01 > Sep > 01 > Evaporator Drain/Exhaust - Hissing Sound Heat Shield: All Technical Service Bulletins Evaporator Drain/Exhaust - Hissing Sound NUMBER: 11-002-01 GROUP: Exhaust DATE: Sept. 14, 2001 SUBJECT: Hissing Sound When Water From The Evaporator Drain Drips On Exhaust OVERVIEW: This bulletin involves installing a revised exhaust system heat shield containing a drain trough to route water away from the exhaust system. MODELS: 2001 (AN) Dakota 2001 (DN) Durango SYMPTOM/CONDITION: A hissing sound may be present when water from the A/C evaporator drain drips onto the exhaust system. DIAGNOSIS: If the condition is present or the customer indicates that the vehicle exhibits the condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. WARNING: THE ENGINE AND EXHAUST SYSTEM MAY BE EXTREMELY HOT. ALLOW SUFFICIENT TIME FOR THE ENGINE AND EXHAUST SYSTEM TO COOL PRIOR TO PERFORMING THIS PROCEDURE. 1. Locate the heat shield in the engine compartment directly above the right side exhaust manifold to front exhaust pipe connection. 2. Remove the two screws attaching the heat shield to the bulkhead and remove the shield. Discard the shield. 3. Install the new shield, P/N 55257336AB, with the drain trough located at the top. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 11-002-01 > Sep > 01 > Evaporator Drain/Exhaust - Hissing Sound > Page 1894 FAILURE CODE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Page 1895 Heat Shield: Description and Operation DESCRIPTION There are two types of heat shields used. One is stamped steel the other is molded foil sheets. The shields attach to the vehicle around the exhaust system. OPERATION The heat shields prevent heat from the exhaust system from entering the passenger area and other areas where the heat can cause damage to other components. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Page 1896 Heat Shield: Service and Repair REMOVAL 1. Raise and support the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Page 1897 2. Remove the screws and nuts holding the heat shields to the frame and floor pan. When removing muffler heat shield, the muffler front and rear support hangers must be removed first. Be sure to disconnect both oxygen sensor connectors. 3. Slide the shield out around the exhaust system. INSTALLATION 1. Position the heat shields to the floor pan or the frame and install the screws and nuts. 2. Tighten the screws/nuts to 7 Nm (60 inch lbs.) torque. Tighten the muffler hangers to 23 Nm (200 inch lbs.) 3. Lower the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Description and Operation Muffler: Description and Operation DESCRIPTION All engines use a stainless steel muffler to control exhaust noise levels and exhaust back pressure. OPERATION The muffler is designed to muffle the sound of the exhaust as if leaves the engine. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Description and Operation > Page 1901 Muffler: Service and Repair REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Remove muffler to exhaust pipe/catalytic converter and tailpipe clamps. 4. Remove tailpipe from hanger isolator. Heat muffler to tailpipe with an oxygen/acetylene torch and twist tailpipe out of muffler. 5. Disconnect muffler from hanger isolators. 6. Heat muffler to exhaust pipe/catalytic converter connection and twist muffler off of converter pipe. INSTALLATION 1. Install muffler to exhaust pipe/catalytic converter and tailpipe. Install exhaust clamps and start nuts by hand. 2. Connect muffler to rear muffler hanger. 3. Connect tailpipe to rear hanger. 4. Align muffler and tighten exhaust clamp nuts to 42 Nm (31 ft. lbs.). 5. Lower vehicle and connect battery negative cable. 6. Start engine and check for exhaust leaks. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions Central Timer Module: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1909 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1910 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1911 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1912 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1913 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1914 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1915 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1916 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1917 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1918 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1919 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1920 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1921 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1922 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1923 Central Timer Module: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1924 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1925 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1926 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1927 Central Timer Module: Electrical Diagrams 8w-45-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1928 8w-45-3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1929 8w-45-4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1930 8w-45-5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1931 8w-45-6 (Base) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1932 8w-45-7 (Light Package) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1933 8w-45-8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1934 8w-45-9 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1935 8w-45-10 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1936 8w-45-11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1937 8w-45-12 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1938 8w-45-13 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1939 8w-45-14 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1940 8w-45-15 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information Central Timer Module: Technician Safety Information WARNING: - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. 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. - NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information > Page 1943 Central Timer Module: Vehicle Damage Warnings Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. 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, Road Testing A Complaint Vehicle Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE REASSEMBLED. DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB III SCREEN WHILE IN MOTION. DO NOT HANG THE DRB III FROM THE REAR VIEW MIRROR OR OPERATE IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB III. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description Central Timer Module: Description and Operation Sytem Description The body system on the 2001 DN consists of a combination of modules that communicate over the PCI bus (Programmable Communication Interface multiplex system). Through the PCI bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all information to perform its function. It will only respond to messages "addressed" to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. All of the information about the functioning of all the systems is organized, controlled, and communicated by the PCI bus, which is described in the vehicle communication of this general information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 1946 Central Timer Module: Description and Operation Functional Operation Part 1 of 2 For additional information on the Base CTM refer to Instrument Panel, Gauges and Warning Indicators / Audible Warning Device. See: Instrument Panel, Gauges and Warning Indicators/Audible Warning Device AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. The Airbag Control Module (ACM) is an electronic module that monitors the airbag system for proper operation, stores diagnostic trouble code (DTCs), controls the airbag warning lamp and contains the sensor and actuator that is responsible for airbag deployment. There are no external impact sensors. The ACM is mounted on a special bracket that is fastened to the floor of the truck at the bottom of the instrument panel. It is located forward of the console. The ACM provides diagnostic information (DTCs) to the technician through the DRB III via the PCI bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp is driven with messages relayed to the Electro/Mechanical Instrument Cluster (EMIC) from the ACM via the PCI bus. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Whenever the ignition key is turned to the "run" or "start" position, the airbag control module performs a lamp check by turning the AIRBAG warning lamp ON for 6 - 8 seconds. If the lamp remains OFF, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains ON, there could be an active fault in the system or the circuit that operates the lamp may be shorted to ground. If the lamp comes ON and stays ON for a period longer than 6 - 8 seconds, then goes OFF, there is usually an intermittent problem in the system. WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. 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. - NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. Seat Belt Tensioner Front seat belt systems incorporate Tensioner Modules (SBT). At the onset of an impact event each tensioner uses a pyrotechnic device, which is triggered simultaneously with the airbags, to rapidly retract the seat belts. With the slack removed, the occupant's forward motion in an impact will be reduced as will the likelihood of contacting interior components. After an impact that deploys the airbag, the seat belt tensioner assembly must be replaced. The ACM module monitors the Seat Belt Tensioners circuit resistance and reports active and stored DTC's if any problem is found. Airbag Diagnostic Trouble Codes Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB III. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures, diagnostic trouble codes are used as a diagnostic tool. Active Codes The code becomes active as soon as the malfunction is detected and stored after one minute of occurrence or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 1947 of 12 seconds or as long as the malfunction is present. Stored Codes Airbag codes are automatically stored in the ACM's memory after one minute of occurrence or when the ignition is turned OFF. The exception is the "Loss of Ignition Run Only" code which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored as long as the malfunction exists. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, that diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "ON" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. AUDIO SYSTEM The factory installed radio receiver communicates on the Programmable Communication Interface (PCI) data bus network through a separate two-way wire harness connector. This is used for the remote radio switches that are mounted to the steering wheel, and also used for radio diagnosis with the DRB III. The remote radio switches are resistor multiplexed units that are hard wired to the CTM through the clockspring. The CTM monitors the status of the remote radio switches and sends the proper switch status messages on the PCI data bus network to the radio receiver. The electronic circuitry within the radio is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. When troubleshooting output shorts or "output" error messages, the following applies: On radios without an external amplifier, the term "output" refers to the path between the radio and the speaker. This type of circuit can be monitored all the way through the speaker connections by the radio assembly. When the radio displays a shorted output DTC with this type of system, the speaker, radio or wiring could be at fault. The output DTC could refer to a front or rear output or a left or right output. The reason for the difference is the pairing of the output sections of the radio. Some are paired left and right, others are paired front and rear. On radios with an external amplifier, the term "output" refers to the circuit between the radio connector and the amplifier. The radio is capable of monitoring only this portion and can tell nothing about the circuit between the amplifier and the speakers. Consequently, a shorted output DTC on this type of system would only refer to this circuit. A faulty speaker could not cause this DTC. CENTRAL TIMER MODULE The Durango (DN) utilizes a Central Timer Module (CTM). This system is available in a Base or Highline configuration. The CTM performs most of the typical functions a Body Control Module would perform. The Base and Highline CTM provides the following features: Battery Saver Functions For Exterior and Interior Lamps - Cargo Lamps - Chime Warning - Courtesy Lamps - Dome Lamps - Dome Defeat - Door Ajar Switch Status - Fog Lamps - Head Lamp Time Delay - Intermittent Wiper Controls - Low and High Beam Head Lamps - Optical Horn - Park Lamps Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 1948 Additional features of Highline CTM - Central Locking (VTSS) - Door Lock Inhibit - Driver Door Unlock - Enhanced Accident Response - Power Door Locks - Remote Radio - Remote Keyless Entry - Vehicle Theft Alarm (VTSS) The Central Timer Module is located behind the left side kick panel. It contains 26-way, 16-way and 12-way connectors. CHIME SYSTEM The chime system is built into the CTM. There are two chime rates, Low: 50 chimes per minute for reminders and High: 180 chimes per minute for serious conditions that require immediate attention. The high rate chime sounds when the key is left in the ignition and the driver's door is open or if the headlights or the courtesy lights are left on. The low rate chime sounds for any of the other conditions. There is a variable rate feature that allows the chime to sound continuously for key-in and headlamp warning as long as the door is open. The seat belt warning chime is activated for six seconds, and all other chime conditions will activate the chime once at the same time the warning light on the cluster is illuminated. The Chime will sound for the following conditions: Ignition OFF key in ignition, driver's door open - Ignition OFF, headlamps ON, driver's door open - Ignition OFF, courtesy lamps ON, driver's door open - Seat belt warning (after prove-out) - Malfunction Indicator lamp (MIL) illuminated (after prove-out) - Airbag lamp illuminated (after prove-out) - Check gauges lamp - Low fuel warning - Low washer fluid lamp - Door ajar warning - Transmission temperature lamp - Turn signal on reminder warning - Button pushed on compass mini-trip computer COMPASS MINI-TRIP COMPUTER (CMTC) This system, located in the overhead console, displays information on outside temperature, compass direction and trip information. Compass and Temperature Display This display provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. Trip Odometer (ODO) Shows the distance traveled since the last reset. Average Fuel Economy (AVE ECO) Shows the average fuel economy in MPG (miles per gallon) or L/100 Km since the last reset. Instant Fuel Economy Shows the fuel economy for the last few seconds in MPG or L/100 Km. Distance to Empty (DTE) Shows the estimated distance that can be traveled with the fuel remaining in the tank. This is calibrated using the MPG for the last few minutes. Elapsed Time (ET) Shows the accumulated ignition ON time since the last reset. Step Button Press this button to cycle through all the mini-trip computer displays. US/M Button Press this button to convert all vehicle displays from US to Metric to US. To Reset the Display Press the Step and US/M buttons simultaneously for at least two seconds and all resettable conditions will be reset. This will occur only if a resettable function (AVG ECO, ECO, ET) is currently being displayed. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 1949 Automatic Compass Calibration This compass is self calibrating which eliminates the need to manually set the compass. When the vehicle is new, the compass may appear erratic and the CAL symbol will be displayed. After completing three 360' turns in an area free from large metal or metallic objects, the CAL symbol will turn OFF and the compass will function normally. Compass Variance Compass Variance is the difference between Magnetic North and Geographic North. In some areas of the country, the difference between Magnetic and Geographic North is great enough to cause the compass to give false readings. If this occurs, the compass variance must be set. To Set the Variance Turn the ignition ON and set display to Comp./Temp. while pressing the US/M button, press the STEP button for approximately five seconds. The "VAR" symbol will light and the last variance zone number will be displayed. Press the US/Metric Button to select the proper variance zone as shown on the map. Press the Step button to set the new variance zone and resume normal operation. ELECTRO/MECHANICAL INSTRUMENT CLUSTER (EMIC) The Instrument Cluster contains a Fuel, Voltmeter, Coolant Temp, and Oil Pressure gauge, a Tachometer and a Speedometer. With the exception of the Voltmeter, the cluster positions the gauges with PCI Bus messages received from the PCM. The Voltmeter operates directly off of the Fused B+ Switched Ignition Output circuit that supplies ignition voltage for the cluster. The Instrument Cluster also contains warning indicators that are illuminated by hard wired inputs or by messages received from other modules on the PCI Bus. The Trip/Total Odometer is a Vacuum Fluorescent Display (VF) that is controlled by PCI Bus messages received from the PCM. The cluster illumination lamps are hard wired in the Instrument Cluster. When the Park or Headlamps are turned ON, the cluster receives a dimmed battery feed from the Headlamp Switch. The cluster I/O Processor controls the VF display dimming and also sends dimming level messages on the PCI Bus. The EMIC will communicate with the DRB III to display PCI Engine Info, PCI Bus Info, and certain input/outputs. Cluster diagnostic capabilities that the DRB III will actuate are limited to the Cluster Calibration Points for the gauges. The DRB III can also extract active and stored Diagnostic Trouble Codes (DTC) from the Instrument Cluster. The EMIC is also capable of performing a diagnostic Self-Test that is actuated by depressing and holding the Odometer trip reset stalk while cycling the ignition from the OFF to the ON position. After the cluster Odometer displays CHEC, releasing the reset stalk begins the test. The cluster will then position all of the gauges at specified calibration points and will illuminate all the PCI Bus controlled indicators. The cluster will also illuminate each segment of the VF display. The EMIC can verify communications with the PCM, ID the module, or change the country code using the DRB III. ENHANCED ACCIDENT RESPONSE (HIGHLINE CTM ONLY) If the Airbag Control Module (ACM) deploys the airbags, a message is transmitted over the PCI bus to the CTM module to unlock the doors. The interior lights will be turned ON when the vehicle speed message on the PCI bus indicates 0 mph or the message is not present. In addition to unlocking the doors, the door lock feature will be disabled for a predetermined amount of time following the deployment. Once the ignition key has been cycled to the "OFF" position, normal operation will resume. EXTERIOR LIGHTING The low and high beam headlamps are controlled directly by an output from the Central Timer Module (CTM). The park lamps and fog lamps (on vehicle so equipped) are controlled via external relays that are energized by the CTM. The headlamp switch provides the control signal through the multifunction switch to the CTM, which indicates low or high beam operation. The Optical Horn (Flash to Pass) feature operates both the high beam and low beam headlamps. The CTM provides the Headlamp Time Delay feature. To start the delay, turn the ignition OFF while the headlamps are ON. Then turn the headlamp switch to the OFF position. This has to be done within 45 seconds of the ignition being turned OFF. The headlamps will remain ON for 60 ± 5 seconds. If during this delay period the headlamp switch is turned ON and then OFF, or ignition switch is turned ON delay will be canceled and they will turn OFF immediately. During the delay period, only headlamps are turned ON and park lamps/fog lamps are turned OFF. The CTM also provides battery protection to avoid wearing down the battery if the customer leaves the park lamps or headlamps ON for extended period of time with the ignition OFF. If the park lamps or headlamps remain ON for more than 5 minutes while the ignition is OFF, the headlamps and park lamps shall be turned off and the input causing the lamps to be ON will be ignored until the input is corrected. Once the 5 minute timeout has extinguished the headlamps and park lamps, any change in the ignition switch, door ajar switches, headlamps switch or park lamp switch will reset the 5 minute timer and return the headlamps and park lamps to normal operation. Part 2 of 2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 1950 HEATING & A/C SYSTEM The all-new heating and air conditioning system for DN provides more heating and cooling capacity than in previous years. Depending on the model, either a Dual-Zone Air Conditioning System or a Three-Zone Air Conditioning System is currently available in these vehicles. Air Distribution (Front) The front compartment HVAC unit has four fully adjustable instrument panel outlets. Side-window demister outlets in the instrument panel eliminate the need for door ducts and door-to-instrument panel seals. A single central mounted outlet delivers air for defrosting the windshield. Two outlets, one on each side of the center console underneath the instrument panel, provide airflow to the driver floor area and to the front seat passenger floor area. While two additional outlets, one on each side of the center console near the rear of the front seats, distribute both heated and cooled air across the floor to the intermediate seat passengers. Ducts in the center of the vehicle underneath the carpet deliver air from the front compartment HVAC unit to the two intermediate passenger outlets. Door Actuator Control A simplified control system for operation of the mode, recirculation, and temperature control actuators provides positive positioning without the complexity of feedback from position sensors. The A/C - Heater Control Module knows the number of operating actuator revolutions required for full door travel as well as the number of actuator commutator pulses per revolution. Using these parameters, the A/C - Heater Control Module runs the actuator for the number of commutator pulses that correspond to the desired door position. To maintain accuracy, the system recalibrates itself periodically at known zero and full travel conditions. The dual sliding Blend switches have multiple detents to control the full range of temperature that the system can produce in any mode. On Dual-Zone systems, the upper slide pot controls the driver-side blend door and the lower slide pot controls the passenger-side blend door. On Three-Zone systems, the upper slide pot controls the driver-side blend door, while the lower slide pot controls the passenger-side blend door and the rear A/C - heater unit blend door. The single rotary Mode switch has 12 detents to either direct airflow to the panel outlets, to a mix of floor and panel outlets, to the floor outlets, to a mix of floor and defrost outlets, or to the defrost outlet. Rotating the Mode switch to either of the two MAX positions results in the A/C - Heater Control Module sending a signal to the recirculation actuator to close the fresh-air door. While rotating the Mode switch to any other position results in the A/C - Heater Control Module sending a signal to the recirculation actuator to open the fresh-air door. When the Blower switch is OFF, the A/C - Heater Control Module closes the fresh-air door to prevent outside air from entering the vehicle. On Three- Zone systems, the Mode switch also controls the rear A/C - heater unit mode door, which directs rear airflow either to the right quarter trim panel outlet or to the overhead outlets. Front Blower Control The front blower circuitry employs a new resistor technology to control front blower speed. Called the "credit card" resistor, the device looks much like its name in that it is thin and compact like a credit card. The credit card resistor, like the coil resistor used in previous years, mounts inside the front HVAC housing assembly in the airflow path. However, unlike the coil resistor, the credit card resistor offers much less airflow restriction. A/C Operation The A/C - Heater Control Module monitors the temperature of the evaporator to keep it just above freezing for maximum cooling and dehumidification. A thermistor (temperature variable resistor) placed between the evaporator fins provides the signal for the control. The Powertrain Control Module (PCM) cycles the compressor on and off with a signal from the A/C - Heater Control Module. Heater Operation To assist the HVAC system in maintaining a consistent and optimum heat output at low vehicle speeds, an electric coolant pump operates under specific conditions to keep a steady flow of hot coolant circulating through the heater circuit. The A/C - Heater Control Modules controls the operation of the electric coolant pump. The pump runs when all of the following conditions are met: When the vehicle's speed is below 27 Km/h (17 mph), the coolant temperature is between 65.5 °C and 110 °C (150 °F and 230 °F), and the blend control is set above 60% reheat. The A/C - Heater Control Module turns the pump OFF if any one of the following conditions occur: The vehicle speed rises above 48.3 Km/h (30 mph). The coolant temperature drops below 65.5 °C (150 °F). The coolant temperature rises above 110 °C (230 °F). The blend control is set below 60% reheat. A/C - Heater Control (Rear) The Three-Zone system allows the intermediate seat occupants to regulate the air temperature and the fan speed of the rear unit from the rotary controls on the headliner mounted Rear A/C - Heater Control. HVAC Diagnostics The A/C - Heater Control Module is fully addressable with the DRB III. Two of the Control Module's diagnostic capabilities that the DRB III will actuate include the A/C Cool down Test to test A/C system performance and the HVAC Door Recalibration Test to determine actuator travel span. After performing either test, the Control Module will display one or more messages on the DRB III screen. The message will indicate either that the HVAC system passed the test or that there is a fault currently active in the HVAC system. The DRB III can also extract active and stored Diagnostic Trouble Codes (DTCs) from the control module. Active DTCs are faults that currently exit in the HVAC system. Stored DTCs are faults that occurred in the HVAC system since the control module received the last "clear diagnostic info" message. INTERIOR LIGHTING Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 1951 The Courtesy lights and illuminated entry feature are controlled by the Central Timer Module (CTM). The CTM will activate the courtesy lamps, including Map Lights and the Dome Lights when either the dome lamp switch is turned ON or a door is opened. The courtesy lamps will fade to OFF immediately when all doors are closed with the dome lamp switch in the OFF position. The illuminated entry feature operates under the following conditions: RKE "unlock" - Driver/Passenger door is opened - Unlocking either the driver or passenger using the key (vehicles equipped with security system) - The dome lamp switch is turned ON Once activated, the illuminated entry will "fade to OFF" after 3 to 5 seconds under the following conditions: All doors are closed and: RKE "lock signal is received or - Manual actuated power "lock" signal is received or - Ignition switch is turned to the ON position or - 30 seconds have elapsed without any other action Addition RKE unlock actuation before the expiration of illuminated entry will not reset timer. Opening any door before the 30 second timer expires, will reset the entry time to 30 seconds and the illuminated entry timer will not begin counting down again until all doors are closed. The Cargo lamps are controlled by the CTM. Placing the dome lamp switch in the cargo lamp position grounds an input to the CTM. The CTM then sends voltage to the cargo lamps. The Interior lamp defeat feature will not allow any interior lamp to be turned ON. This is accomplished through an input to the CTM from the dome lamp switch. The CTM provides battery protection by shutting down the interior lamps due to the following. Leaving a door open, dome lamp switch ON, reading/vanity lamp switch ON or glove box door open for more than 15 minutes while the ignition is OFF. POWER DOOR LOCKS/REMOTE KEYLESS ENTRY The CTM controls the door lock actuator assemblies to handle locking and unlocking with the key fob or interior switch. Vehicles that are equipped with the Vehicle Theft Security System will also have the central locking feature. With the central locking feature, when the cylinder lock switch is turned to the lock position all the doors will lock. For unlocking, if the key is turned to the unlock position once, only that door will unlock. If the key is then turned a second time to the unlock position, all the doors will unlock. There is also a door lock inhibit feature that prevents power locking of the doors if the ignition is OFF and the key is in the ignition. Automatic or "rolling locks" are included as a programmable feature. If the vehicle is moving approximately 15 mph and approximately 10 degrees of throttle opening is seen by the PCM, (the PCM will send this info to the CTM via the PCI bus) indicating acceleration, the CTM will cycle the lock actuators to lock the doors. The highline CTM provides for Remote Keyless Entry (RKE) The RKE system is placed in the programming mode by the DRB III, or by the customer program features. The system will store up to four key fob codes. Two fobs are supplied with the truck, additional fobs may be purchased through the parts department. Through the DRB III, erasing and programming of one key fob without deleting the others is possible. If the key fob is stolen, all the fob codes stored previously may be erased to provide the owner of the vehicle with an extra sense of security. VEHICLE COMMUNICATION The Programmable Communication Interface or PCI Bus is a single wire multiplexed network capable of supporting binary encoded messages shared between multiple modules. The PCI bus circuit is identified as D25 and is violet with a yellow tracer. Additional tracer colors may be added to the yellow in order to distinguish between different module connections. The modules are wired in parallel. Connections are made in the harness using a splice. The splice called the Diagnostic Junction Port, serves as the "Hub" of the bus. The Diagnostic Junction Port provides an access point to isolate most of the modules on the bus in order to assist in diagnosing the circuit. The following modules are used on the DN: Airbag Control Module - A/C Heater Control - Central Timer Module - Controller Antilock Brake - Compass Mini-Trip Computer - Electro/Mechanical Instrument Cluster - Powertrain Control Module - Radio Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 1952 - Sentry Key Immobilizer Module - Transfer Case Control Module - Transmission Control Module Each module provides its own bias and termination in order to transmit and receive messages. The bus voltage is at zero volts when no modules are transmitting and is pulled up to about seven and a half volts when modules are transmitting. The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRB III lab scope. The 12v square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between zero and about seven and a half volts. Refer to the figure for some typical displays. The PCI Bus failure modes are broken down into two categories. Complete PCI Bus Communication Failure and individual module no response. Causes of complete PCI Bus Communication Failure include a short to ground or battery on the PCI circuit. Individual module no response can be caused by an open circuit at either the Diagnostic Junction Port or the module, or an open battery or ground circuit to the affected module. Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: All gauges on the EMIC stay at zero - All telltales on EMIC illuminate - EMIC backlighting at full intensity - Dashed lines in the Compass Mini-Trip Computer display Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 1953 - No response received from any module on the PCI bus (except the PCM) - No start (if equipped with Sentry Key immobilizer) Symptoms of Individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRB III. Diagnosis starts with symptom identification. If a complete PCI Bus Communication Failure is suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRB III. If any modules are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI circuit or power supply and ground circuits. The DRB III may display "BUS +A SIGNAL OPEN" or "NO RESPONSE" to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRB III and in no way indicates whether or not the PCI bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped. VEHICLE THEFT SECURITY SYSTEM The VTSS system monitors the door ajar switches, and ignition switch to detect unauthorized entry into the vehicle. Once the vehicle is "armed", any one of these inputs can cause the VTSS system to be tripped. Once tripped, the horn and lights will pulse for 3 minutes and if an attempt is made to start the engine with a non-programmed SKIM key, it will start and stall. If the trigger condition is still present, the lights will continue to flash for an additional 15 minutes, after which the system will stop pulsing the lights and return to the "armed" state. The cause of the last 4 alarm triggers is stored by the CTM and may be retrieved by the DRB III. The system may be disarmed by either an unlock command from a valid RKE key fob by using a key in either door, or by using a valid SKIM key in the ignition. The door key cylinders are equipped with disarm switches. There is also a VTSS lamp on the dash that provides information to the driver about the state of the vehicle theft system. WINDSHIELD WIPER SYSTEM The DN truck is equipped with speed sensitive intermittent wipers. The low and high speeds are controlled through the wiper stalk switch. The intermittent portion of the wiper control is handled by the CTM through the intermittent wiper relay. When the module detects a decrease in delay time as selected by the driver, an immediate wipe of the windshield takes place and the new delay interval is implemented. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Central Timer Module: Symptom Related Diagnostic Procedures Non-Trouble Code Procedures For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. The hard wired inputs to and outputs from the Central Timer Module (CTM) may be diagnosed and tested using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the CTM. In order to obtain conclusive testing of the CTM, the Programmable Communications Interface (PCI) data bus network and all of the electronic modules that provide inputs to or receive outputs from the CTM must also be checked. The most reliable, efficient, and accurate means to diagnose the CTM, the PCI data bus network, and the electronic modules that provide inputs to or receive outputs from the CTM requires the use of a DRB III scan tool. Refer to the appropriate diagnostic information. The DRB III scan tool can provide confirmation that the PCI data bus network is functional, that all of the electronic modules are sending and receiving the proper messages over the PCI data bus, and that the CTM is receiving the proper hard wired inputs and responding with the proper hard wired outputs needed to perform its many functions. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: The following tests may not prove conclusive in the diagnosis of the Central Timer Module (CTM). The most reliable, efficient, and accurate means to diagnose the CTM requires the use of a DRB III scan tool. Refer to the appropriate diagnostic information. 1. Check the fused B(+) fuses (Fuse 3 - 20 ampere, and Fuse 12 - 20 ampere) in the Power Distribution Center (PDC). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fused B(+) fuses (Fuse 3 - 20 ampere, and Fuse 12 - 20 ampere) in the PDC. If OK, go to Step 3. If not OK, repair the open B(+) circuit between the PDC and the battery as required. 3. Disconnect and isolate the battery negative cable. Disconnect the instrument panel wire harness connector (Connector C3) for the CTM from the CTM connector receptacle. Reconnect the battery negative cable. Check for battery voltage at each of the two fused B(+) circuit cavities of the instrument panel wire harness connector (Connector C3) for the CTM. If OK, disconnect and isolate the battery negative cable, reconnect the instrument panel wire harness connector (Connector C3) for the CTM to the CTM connector receptacle, and go to Step 4. If not OK, repair the open fused B(+) circuit(s) between the CTM and the PDC as required. 4. Check the fused ignition switch output (run-start) fuse (Fuse 11 - 10 ampere) and the fused ignition switch output (run-acc) fuse (Fuse 5 - 20 ampere) in the Junction Block (JB). If OK, go to Step 5. If not OK, repair the shorted circuit or component as required and replace the faulty fuse(s). 5. Reconnect the battery negative cable. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run-start) fuse (Fuse 11 - 10 ampere) and the fused ignition switch output (run-acc) fuse (Fuse 5 20 ampere) in the JB. If OK, go to Step 6. If not OK, repair the open fused ignition switch output (run-start) circuit or fused ignition switch output (run-acc) circuit between the JB and the ignition switch as required. 6. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the instrument panel wire harness connector (Connector C1) for the CTM from the CTM connector receptacle. Reconnect the battery negative cable. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run-start) circuit cavity and the fused ignition switch output (run-acc) cavity of the instrument panel wire harness connector (Connector C1) for the CTM. If OK, go to Step 7. If not OK, repair the open fused ignition switch output (run-start) circuit or fused ignition switch output (run-acc) circuit between the CTM and the JB as required. 7. Turn the ignition switch to the OFF position. Check for continuity between each of the three ground circuits in the instrument panel wire harness connector (Connector C1) for the CTM and a good ground. In each case there should be continuity. If OK, use a DRB III scan tool to perform further diagnosis of the CTM. Refer to the appropriate diagnostic information. If not OK, repair the open ground circuit(s) to ground (G207 or G208) as required. Chime Inoperative At All Times Test 1 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1956 SYMPTOM CHIME INOPERATIVE AT ALL TIMES POSSIBLE CAUSES - CTM - Chime inoperative Chime Inoperative With Drivers Seat Belt Unfastened Tests 1 - 4 SYMPTOM CHIME INOPERATIVE WITH DRIVER SEAT BELT UNFASTENED POSSIBLE CAUSES - Seat belt switch status wrong - Seat belt switch shorted - Seat belt indicator driver wire short to ground - Instrument cluster - seat belt switch shorted Chime Inoperative With Key In Ignition and Driver's Door Open Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1957 Tests 1 - 4 Test 5 SYMPTOM CHIME INOPERATIVE WITH KEY IN IGNITION, DRIVER'S DOOR OPEN POSSIBLE CAUSES - Driver door ajar status - Ignition switch ground circuit open - Key-in ignition switch open - Key-in ignition switch sense circuit open - Central timer module Chime Inoperative, Exterior/Interior Lamps On, Driver Door Open Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1958 Tests 1 - 2 SYMPTOM CHIME INOPERATIVE WITH EXTERIOR OR INTERIOR LAMPS ON WITH DRIVER DOOR OPEN POSSIBLE CAUSES - DRB check driver door ajar - CTM-chime inoperative with headlamp switch - Operation of exterior or interior lighting system Chime Sounds With Driver Seat Belt Fastened Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1959 Tests 1 - 4 Test 5 SYMPTOM CHIME SOUNDS WITH DRIVER SEAT BELT FASTENED POSSIBLE CAUSES - Seat belt switch status wrong - Seat belt switch open - Ground wire open - Seat belt indicator driver wire open - Instrument cluster - seat belt sense open Chime Sounds With Drivers Door Open and Key Removed From Ignition Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1960 Tests 1 - 4 SYMPTOM CHIME SOUNDS WITH DRIVER'S DOOR OPEN, KEY REMOVED POSSIBLE CAUSES - Operation of exterior or interior lighting system - Key-in ignition switch shorted - Key-in ignition SW sense short to ground - Central timer module - key-in ignition shorted Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1961 Central Timer Module: Component Tests and General Diagnostics Road Testing A Complaint Vehicle ROAD TEST WARNINGS Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the test drive, do not try to read the DRB III screen while in motion. Do not hang the DRB III from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB III. Six Step Troubleshooting Procedure SIX-STEP TROUBLESHOOTING PROCEDURE Diagnosis is done in six basic steps: 1. Verification of complaint 2. Verification of any related symptoms 3. Symptom analysis 4. Problem isolation 5. Repair of isolated problem 6. Verification of proper operation Vehicle Preparation For Testing VEHICLE PREPARATION FOR TESTING Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1962 Central Timer Module: Scan Tool Testing and Procedures DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB III will display one of only two error messages: User-Requested WARM Boot (Press MORE and NO at the same time) User-Requested COLD Boot (Press MORE and YES at the same time) If the DRB III should display any other error message, record the entire display and call the S.T.A.R. Center for information and assistance. DRB III DOES NOT POWER UP If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB III. If all connections are proper between the DRB III and the vehicle or other devices, and the vehicle battery is fully charged, and inoperative DRB III may be the result of faulty cable or vehicle wiring. For a blank screen, refer to the appropriate body diagnostics. DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition SOME DISPLAY ITEMS READ "---" This is caused by scrolling the DRB III display a single line up or down. The line which was scrolled onto the screen might read "---". Use the Page Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1963 Down or Page Up function to display the information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Page 1964 Central Timer Module: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: Before replacing a Central Timer Module (CTM), use a DRB III scan tool to retrieve the current settings for the CTM programmable features. Refer to the appropriate diagnostic information. These settings should be duplicated in the replacement CTM using the DRB III scan tool before returning the vehicle to service. 1. Disconnect and isolate the battery negative cable. 2. Remove the trim from the left cowl side inner panel. Fig. 2 Central Timer Module 3. Disconnect the two instrument panel wire harness connectors and one body wire harness connector from the CTM connector receptacles. 4. Remove the three screws that secure the CTM to the left cowl side inner panel. 5. Remove the CTM from the left cowl side inner panel. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: Before replacing a Central Timer Module (CTM), use a DRB III scan tool to retrieve the current settings for the CTM programmable features. Refer to the appropriate diagnostic information. These settings should be duplicated in the replacement high-line/premium CTM using the DRB III scan tool before returning the vehicle to service. 1. Position the CTM onto the left cowl side inner panel. 2. Install and tighten the three screws that secure the CTM to the left cowl side inner panel. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the two instrument panel wire harness connectors and one body wire harness connector to the CTM connector receptacles. 4. Reinstall the trim onto the left cowl side inner panel. 5. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Page 1965 Central Timer Module: Tools and Equipment DRB III (Diagnostic Read-out Box) Jumper Wires Ohmmeter Voltmeter Test Light Diagnostic Junction Port Tester 8310 Airbag Load Tool 8443 Airbag Load Tool Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Customer Interest: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts Powertrain Control Module: Customer Interest A/T - 45RFE/545RFE Harsh Upshifts/Downshifts NUMBER: 18-025-01 GROUP: Vehicle Performance DATE: October 15, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-09-00, DATED SEPTEMBER 15, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. **ASTERISKS** HAVE BEEN USED TO HIGHLIGHT CHANGES. THIS BULLETIN ADDS A MODEL YEAR AND REQUIRES A REPROGRAMMING OF THE 1999 AND 2000 GRAND CHEROKEE POWERTRAIN CONTROL MODULE (PCM). SUBJECT: 45RFE **and 545RFE Shift** Quality Enhancements for the** 2-3, 4-5, and 5-4** Shifts OVERVIEW: This bulletin involves selectively erasing and reprogramming the **Transmission Control Module (TCM) with new software: '99-'01 WJ (PN 05019701AC Ver 9.3), '00 AN/DN (PN 05018454AB Ver 9.1), or '01 AN/DN (PN 56028285A1 Ver 8.4), and requires reprogramming of the Powertrain Control Module (PCM) for the 1999 and 2000 Grand Cherokees only (with calibration 99Cal20 (1999) or 00Cal17 (2000).** NOTE: THE 2001 GRAND CHEROKEE DOES NOT REQUIRE REPROGRAMMING OF THE PCM AS IT IS ALREADY AT THE CORRECT CALIBRATION LEVEL. NOTE: WHENEVER A PCM OR TCM IS REPLACED OR REPROGRAMMED, THE SOFTWARE OF THE PCM MUST BE VERIFIED AS HAVING THE LATEST REVISION LEVEL. MODELS: 2000 (AN) Dakota **2001** 2000 (DN) Durango **2001** 1999 (WJ) Grand Cherokee **2001 ** NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 4.7L ENGINE AND A 45RFE **OR 545RFE** TRANSMISSION. SYMPTOM/CONDITION: Some vehicles **may exhibit one or more of the following performance conditions **: 1. A harsh 2-3 upshift causing a powertrain clunk or shudder when accelerating. 2. **A harsh 4-5 upshift ('01 Grand Cherokee only).** 3. **A harsh 5-4 downshift ('01 Grand Cherokee only).** NOTE: THIS REVISION TO THE TCM SOFTWARE ADDRESSES THE ABOVE SHIFT QUALITY CONDITIONS FOR ALL VEHICLES AND, ADDS A FINAL GEAR RATIO TO THE **1999 AND 2000 MY** GRAND CHEROKEE TRANSMISSION ONLY. (2001 MY GRAND CHEROKEE ALREADY HAS THIS UPGRADE.) NOTE: TO MAINTAIN EMISSIONS COMPLIANCE, GRAND CHEROKEE VEHICLES THAT ARE EQUIPPED WITH A FEDERAL EMISSION SYSTEM (SALES CODE NAA) MUST HAVE THEIR PCM REPROGRAMMED. IF THE SOFTWARE LEVEL IS AT OR HIGHER THAN THOSE IN THE OVERVIEW ABOVE, OR IF THE GRAND CHEROKEE HAS A CALIFORNIA EMISSIONS SYSTEM (SALES CODE NAE), REPROGRAMMING IS NOT NECESSARY. DIAGNOSIS PROCEDURES: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRBIII(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 performing this repair. If no DTC's are present, and the above symptom has been experienced, perform the Repair Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Customer Interest: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts > Page 1974 Procedure. NOTE: **IF OTHER PERFORMANCE ISSUES REMAIN AFTER THE REPAIR PROCEDURE HAS BEEN PERFORMED THEY DO NOT RELATE TO THIS BULLETIN. REFER TO THE PROPER SERVICE OR DIAGNOSTIC PROCEDURES MANUAL(S) FOR FURTHER ASSISTANCE.** PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD **2093 OR HIGHER AND DRB III(R) VERSION 52.3 WILL BE IN THE DEALERSHIPS ON OCTOBER 15, 2001.)** REPAIR PROCEDURE: 1. Log onto the MDS2 (Mopar Diagnostic System). 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III(R), MDS2, AND VEHICLE ESTABLISH COMMUNICATION. 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. 3. Push the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) 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. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. 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, 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 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Customer Interest: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts > Page 1975 7. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 8. 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > All Technical Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Powertrain Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > All Technical Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 1981 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > All Technical Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 1982 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > All Technical Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 1983 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > All Technical Service Bulletins for Powertrain Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts Powertrain Control Module: All Technical Service Bulletins A/T - 45RFE/545RFE Harsh Upshifts/Downshifts NUMBER: 18-025-01 GROUP: Vehicle Performance DATE: October 15, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-09-00, DATED SEPTEMBER 15, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. **ASTERISKS** HAVE BEEN USED TO HIGHLIGHT CHANGES. THIS BULLETIN ADDS A MODEL YEAR AND REQUIRES A REPROGRAMMING OF THE 1999 AND 2000 GRAND CHEROKEE POWERTRAIN CONTROL MODULE (PCM). SUBJECT: 45RFE **and 545RFE Shift** Quality Enhancements for the** 2-3, 4-5, and 5-4** Shifts OVERVIEW: This bulletin involves selectively erasing and reprogramming the **Transmission Control Module (TCM) with new software: '99-'01 WJ (PN 05019701AC Ver 9.3), '00 AN/DN (PN 05018454AB Ver 9.1), or '01 AN/DN (PN 56028285A1 Ver 8.4), and requires reprogramming of the Powertrain Control Module (PCM) for the 1999 and 2000 Grand Cherokees only (with calibration 99Cal20 (1999) or 00Cal17 (2000).** NOTE: THE 2001 GRAND CHEROKEE DOES NOT REQUIRE REPROGRAMMING OF THE PCM AS IT IS ALREADY AT THE CORRECT CALIBRATION LEVEL. NOTE: WHENEVER A PCM OR TCM IS REPLACED OR REPROGRAMMED, THE SOFTWARE OF THE PCM MUST BE VERIFIED AS HAVING THE LATEST REVISION LEVEL. MODELS: 2000 (AN) Dakota **2001** 2000 (DN) Durango **2001** 1999 (WJ) Grand Cherokee **2001 ** NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 4.7L ENGINE AND A 45RFE **OR 545RFE** TRANSMISSION. SYMPTOM/CONDITION: Some vehicles **may exhibit one or more of the following performance conditions **: 1. A harsh 2-3 upshift causing a powertrain clunk or shudder when accelerating. 2. **A harsh 4-5 upshift ('01 Grand Cherokee only).** 3. **A harsh 5-4 downshift ('01 Grand Cherokee only).** NOTE: THIS REVISION TO THE TCM SOFTWARE ADDRESSES THE ABOVE SHIFT QUALITY CONDITIONS FOR ALL VEHICLES AND, ADDS A FINAL GEAR RATIO TO THE **1999 AND 2000 MY** GRAND CHEROKEE TRANSMISSION ONLY. (2001 MY GRAND CHEROKEE ALREADY HAS THIS UPGRADE.) NOTE: TO MAINTAIN EMISSIONS COMPLIANCE, GRAND CHEROKEE VEHICLES THAT ARE EQUIPPED WITH A FEDERAL EMISSION SYSTEM (SALES CODE NAA) MUST HAVE THEIR PCM REPROGRAMMED. IF THE SOFTWARE LEVEL IS AT OR HIGHER THAN THOSE IN THE OVERVIEW ABOVE, OR IF THE GRAND CHEROKEE HAS A CALIFORNIA EMISSIONS SYSTEM (SALES CODE NAE), REPROGRAMMING IS NOT NECESSARY. DIAGNOSIS PROCEDURES: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRBIII(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 performing this repair. If no DTC's are present, and the above symptom has been experienced, perform the Repair Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > All Technical Service Bulletins for Powertrain Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts > Page 1988 Procedure. NOTE: **IF OTHER PERFORMANCE ISSUES REMAIN AFTER THE REPAIR PROCEDURE HAS BEEN PERFORMED THEY DO NOT RELATE TO THIS BULLETIN. REFER TO THE PROPER SERVICE OR DIAGNOSTIC PROCEDURES MANUAL(S) FOR FURTHER ASSISTANCE.** PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD **2093 OR HIGHER AND DRB III(R) VERSION 52.3 WILL BE IN THE DEALERSHIPS ON OCTOBER 15, 2001.)** REPAIR PROCEDURE: 1. Log onto the MDS2 (Mopar Diagnostic System). 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III(R), MDS2, AND VEHICLE ESTABLISH COMMUNICATION. 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. 3. Push the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) 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. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. 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, 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 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > All Technical Service Bulletins for Powertrain Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts > Page 1989 7. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 8. 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > All Other Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Powertrain Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > All Other Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 1995 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > All Other Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 1996 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > All Other Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 1997 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 1998 Powertrain Control Module: Specifications Powertrain Control Module Mounting Screws ................................................................................................................................. 3-5 Nm (30-40 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 1999 Powertrain Control Module: Locations Powertrain Control Module Fig. 9 PCM Location The Powertrain Control Module (PCM) is located in the engine compartment. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2002 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2003 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2004 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2005 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2006 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2007 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2008 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2009 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2010 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2011 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2012 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2013 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2014 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2015 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2016 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2017 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2018 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2019 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2020 Powertrain Control Module: Connector Views Powertrain Control Module C1 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2021 Powertrain Control Module C2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2022 Powertrain Control Module C3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2023 Powertrain Control Module: Electrical Diagrams System Diagrams Refer to Powertrain Management/Diagrams/Electrical for wiring diagrams. See: Diagrams/Electrical Diagrams PCM Communication System Schematic Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2024 2001 Dodge JTEC System Federal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2025 2001 Dodge JTEC System California Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Page 2026 Powertrain Control Module: Description and Operation Fig. 9 PCM Location POWERTRAIN CONTROL MODULE The Powertrain Control Module (PCM) is located in the engine compartment. The PCM is referred to as JTEC. The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. NOTE: PCM Inputs: A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - Auto shutdown (ASD) sense - Battery temperature - Battery voltage - Brake switch - CCD bus (+) circuits - CCD bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for DRB scan tool - Engine coolant temperature sensor - Fuel level - Generator (battery voltage) output - Ignition circuit sense (ignition switch in ON/OFF/crank/run position) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Page 2027 - Intake manifold air temperature sensor - Leak detection pump (switch) sense (if equipped) - Manifold Absolute Pressure (MAP) sensor - Oil pressure - Output shaft speed sensor - Overdrive/override switch - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transmission governor pressure sensor - Transmission temperature sensor - Vehicle speed inputs from ABS or RWAL system NOTE: PCM Outputs: A/C clutch relay - Auto shutdown (ASD) relay - CCD bus (+A) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Generator lamp (if equipped) - Idle Air Control (IAC) motor Ignition coil - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through CCD circuits. - Overdrive indicator lamp (if equipped) - Radiator cooling fan - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through CCD circuits. - Transmission convertor clutch circuit - Transmission 3-4 shift solenoid - Transmission relay - Transmission temperature lamp (if equipped) - Transmission variable force solenoid MODES OF OPERATION As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. For example, the PCM must calculate different injector pulse width and ignition timing for idle than it does for wide open throttle (WOT). The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (O2S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (O2S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to-1 part fuel. By monitoring the exhaust oxygen content through the O2S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise - Acceleration Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Page 2028 - Deceleration - Wide open throttle (WOT) - Ignition switch OFF The ignition switch ON, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. Ignition Switch (KEY-ON) Mode This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: The PCM pre-positions the idle air control (IAC) motor. - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the engine is operating or the starter motor is engaged. - The 02S sensor heater element is energized via the ASD relay. The 02S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. Engine Start-Up Mode This is an Open Loop mode. The following actions occur when the starter motor is engaged.The PCM receives inputs from: Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Starter motor relay - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector ON and OFF. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. Engine Warm-Up Mode This is an Open Loop mode. During engine warmup, the PCM receives inputs from: Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) - Park/neutral switch (gear indicator signal-auto.trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector ON and OFF. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the clutch relay. This is done if A/C has been selected by the vehicle operator and requested by the A/C thermostat. - When engine has reached operating temperature, the PCM will begin monitoring 02S sensor input. The system will then leave the warm-up mode and go into closed loop operation. Idle Mode When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: Air conditioning select signal (if equipped) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Page 2029 - Air conditioning request signal (if equipped) - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector ON and OFF. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio by varying injector pulse width.It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. Cruise Mode When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen (O2S) sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector ON and OFF. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control ('AC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil ON and OFF. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. Acceleration Mode This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. Deceleration Mode When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed sensor If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Page 2030 The PCM adjusts ignition timing by turning the ground path to the coil ON and OFF. Wide Open Throttle Mode This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) During wide open throttle conditions, the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector ON and OFF. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil ON and OFF. ignition switch OFF Mode When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. 5 VOLT SUPPLIES Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. Primary 5-volt supply: supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5-volt supply: supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (if equipped with an RE automatic transmission). IGNITION CIRCUIT SENSE This circuit ties the ignition switch to the Power- train Control Module (PCM). The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Voltage ON the ignition input can be as low as 6 volts and the PCM will still function. Voltage is supplied to this circuit to power the PCM's 8-volt regulator and to allow the PCM to perform fuel, ignition and emissions control functions. POWER GROUND The Powertrain Control Module (PCM) has 2 main grounds. Both of these grounds are referred to as power grounds. All of the high-current, noisy, electrical devices are connected to these grounds as well as all of the sensor returns. The sensor return comes into the sensor return circuit, passes through noise suppression, and is then connected to the power ground. The power ground is used to control ground circuits for the following PCM loads: Generator field winding - Fuel injectors - Ignition coil(s) - Certain relays/solenoids - Certain sensors SENSOR RETURN The Sensor Return circuits are internal to the Powertrain Control Module (PCM). Sensor Return provides a low-noise ground reference for all engine control system sensors. Refer to Power Grounds for more information. SIGNAL GROUND Signal ground provides a low noise ground to the data link connector. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Page 2031 Powertrain Control Module: Service and Repair REMOVAL USE THE DRB SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. Fig. 10 PCM Location And Mounting The PCM is located in the engine compartment. To avoid possible voltage spike damage to the PCM, ignition key must be OFF and negative battery cable must be disconnected before unplugging PCM connectors. 1. Disconnect negative battery cable at battery. 2. Remove cover over electrical connectors. Cover snaps onto PCM. 3. Carefully unplug the three 32-way connectors from PCM. 4. Remove three PCM mounting bolts and remove PCM from vehicle. INSTALLATION USE THE DRB SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. 1. Install PCM and mounting bolts to vehicle. 2. Tighten bolts to 3-5 Nm (30-40 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 cover over electrical connectors. Cover snaps onto PCM. 6. Install battery cable. 7. Use the DRB scan tool to reprogram new PCM with vehicles original Identification Number (VIN) and original vehicle mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Auto Shut Down (ASD) Relay: Locations Power Distribution Center Automatic Shut Down Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2035 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2036 Auto Shut Down (ASD) Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2037 Automatic Shut Down Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2038 Auto Shut Down (ASD) Relay: Description and Operation AUTO SHUT DOWN RELAY PCM Output The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit ON and OFF. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. ASD Sense - PCM Input A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2039 Auto Shut Down (ASD) Relay: Testing and Inspection Fig. 1 ASD And Fuel Pump Relay Terminals - Type 1 Fig. 2 ASD And Fuel Pump Terminals - Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2040 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2041 Auto Shut Down (ASD) Relay: Service and Repair Fig. 3 Power Distribution Center (PDC) Location REMOVAL The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations Oxygen Sensor Relay: Locations Power Distribution Center Oxygen Sensor Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2045 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2046 Oxygen Sensor Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2047 Oxygen Sensor Downstream Heater Relay (California) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2048 Oxygen Sensor Relay: Description and Operation OXYGEN HEATER RELAY The oxygen (O2) sensor heater relay is located in the Powertrain Distribution Center (PDC). Refer to Oxygen Sensor for oxygen sensor relay information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2049 Oxygen Sensor Relay: Service and Repair Fig. 21 Power Distribution Center (PDC) REMOVAL The oxygen sensor heater relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The oxygen sensor heater relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Power Distribution Center Fuel Pump Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2054 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2055 Fuel Pump Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2056 Fuel Pump Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2057 Fuel Pump Relay: Description and Operation The 5-pin, 12-volt, fuel pump relay is located in the Power Distribution Center (PDC). Refer to the label on the PDC cover for relay location. The Powertrain Control Module (PCM) energizes the electric fuel pump through the fuel pump relay. The fuel pump relay is energized by first applying battery voltage to it when the ignition key is turned ON, and then applying a ground signal to the relay from the PCM. Whenever the ignition key is turned ON, the electric fuel pump will operate. But, the PCM will shutdown the ground circuit to the fuel pump relay in approximately 1-3 seconds unless the engine is operating or the starter motor is engaged. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2058 Fuel Pump Relay: Testing and Inspection Fig. 1 ASD And Fuel Pump Relay Terminals - Type 1 Fig. 2 ASD And Fuel Pump Terminals - Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, (Fig. 1) or (Fig. 2). - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2059 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2060 Fuel Pump Relay: Service and Repair Fig. 21 Power Distribution Center (PDC) REMOVAL The fuel pump relay is located in the Power Distribution Center (PDC) (Fig. 21). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The fuel pump relay is located in the Power Distribution Center (PDC) (Fig. 21). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Auto Shut Down (ASD) Relay: Locations Power Distribution Center Automatic Shut Down Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2064 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2065 Auto Shut Down (ASD) Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2066 Automatic Shut Down Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2067 Auto Shut Down (ASD) Relay: Description and Operation AUTO SHUT DOWN RELAY PCM Output The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit ON and OFF. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. ASD Sense - PCM Input A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2068 Auto Shut Down (ASD) Relay: Testing and Inspection Fig. 1 ASD And Fuel Pump Relay Terminals - Type 1 Fig. 2 ASD And Fuel Pump Terminals - Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2069 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2070 Auto Shut Down (ASD) Relay: Service and Repair Fig. 3 Power Distribution Center (PDC) Location REMOVAL The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Fig. 1 Battery Temperature Sensor Location The battery temperature sensor is located under vehicle battery and is attached to a mounting hole on battery tray. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2076 Battery Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2077 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and 02 sensor heater tests). Most OBD II monitors are disabled below 20 degrees F. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2078 Battery Temperature Sensor: Testing and Inspection Tests 1 - 2 SYMPTOM CHECKING THE AMBIENT/BATTERY TEMPERATURE SENSOR POSSIBLE CAUSES - Ambient/Battery temperature sensor - Ambient/Battery temperature sensor (Out Of Calibration) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2079 Battery Temperature Sensor: Service and Repair Fig. 1 Battery Temperature Sensor Location REMOVAL The battery temperature sensor is located under vehicle battery (Fig. 1) and is attached to a mounting hole on battery tray. 1. Remove battery. Refer to Battery for procedures. 2. Disconnect sensor pigtail harness from engine wire harness. Sensor pigtail harness is clipped to vehicle near its electrical connector. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION The battery temperature sensor is located under vehicle battery (Fig. 1) and is attached to a mounting hole on battery tray. 1. Feed pigtail harness through hole in top of battery tray and press sensor into top of battery tray. 2. Connect pigtail harness. 3. Install battery. Refer to Battery for procedures. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Brake Pressure Switch > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor ................................................................................................................... ................................................... 12 Nm (106 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2086 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2087 Camshaft Position Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2088 Camshaft Position Sensor: Description and Operation Fig. 4 CMP Location The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. Fig. 5 CMP Sensor And Tonewheel The CMP sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects notches located on a tonewheel. The tonewheel is located at the front of the camshaft for the right cylinder head. As the tonewheel rotates, the notches pass through the sync signal generator. The pattern of the notches (viewed counter-clockwise from front of engine) is: 1 notch, 2 notches, 3 notches, 3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2089 notches, 2 notches 1 notch, 3 notches and 1 notch. The signal from the CMP sensor 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2090 Camshaft Position Sensor: Service and Repair Fig. 7 CMP Location REMOVAL The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. It is easier to remove/install sensor from under vehicle. 1. Raise and support vehicle. 2. Disconnect electrical connector at CMP sensor. 3. Remove sensor mounting bolt. 4. Carefully pry sensor from cylinder head in a rocking action with two small screwdrivers. 5. Check condition of sensor O-ring. INSTALLATION The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. 1. Clean out machined hole in cylinder head. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into cylinder head with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder head. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in. lbs.) torque. 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications Engine Coolant Temperature (ECT) Sensor: Specifications Engine Coolant Temperature Sensor ....................................................................................................................................................... 11 Nm (96 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2094 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2095 Engine Coolant Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2096 Engine Coolant Temperature (ECT) Sensor: Description and Operation DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: ^ for engine coolant temperature gauge operation through CCD or PCI (J1850) ^ Communications ^ Injector pulse-width ^ Spark-advance curves ^ ASD relay shut-down times ^ Idle Air Control (IAC) motor key-on steps ^ Pulse-width prime-shot during cranking ^ 02 sensor closed loop times ^ Purge solenoid on/off times ^ EGR solenoid on/off times (if equipped) ^ Leak Detection Pump operation (if equipped) ^ Radiator fan relay on/off times (if equipped) ^ Target idle speed Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2097 Engine Coolant Temperature (ECT) Sensor: Service and Repair REMOVAL - 4.7L WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. The ECT sensor is located near the front of the intake manifold. 1. Partially drain cooling system. 2. Disconnect electrical connector from ECT sensor. 3. Remove sensor from intake manifold. INSTALLATION - 4.7L 1. Install sensor. 2. Tighten to 11 Nm (8 ft. lbs.) torque. 3. Connect electrical connector to sensor. 4. Replace any lost engine coolant. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt .............................................................................................................................................................. 28 Nm (21 Ft. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2101 Crankshaft Position Sensor: Locations Fig. 15 CKP Sensor Location The Crankshaft Position (CKP) sensor is located at the right-rear side of the engine cylinder block. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2102 Crankshaft Position Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2103 Crankshaft Position Sensor: Description and Operation Fig. 15 CKP Sensor Location The Crankshaft Position Sensor (CKP) is mounted into the right-rear side of the engine block. 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. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. Fig. 17 CKP Sensor Operation And Tonewheel Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2104 On this engine, a tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2105 Crankshaft Position Sensor: Service and Repair Fig. 19 CKP Sensor Location/Removal/Installation REMOVAL The Crankshaft Position (CKP) sensor is located at the right-rear side of the engine cylinder block. It is positioned and bolted into a machined hole in the engine block. 1. Disconnect CKP electrical connector at sensor. 2. Remove CKP mounting bolt. 3. Carefully pry sensor from cylinder block in a rocking action with two small screwdrivers. 4. Remove sensor from vehicle. 5. Check condition of sensor O-ring. INSTALLATION 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into engine block with a slight rocking action. Do not twist sensor into position as damage to O-ring may result CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 28 Nm (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations Fig. 7 Fuel Gauge Sending Unit Location - Typical Module The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module. The fuel pump module is located inside of fuel tank. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2109 Fuel Level Sensor: Description and Operation FUEL LEVEL SENDING UNIT / SENSOR The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation: A constant input voltage source of about 12 volts (battery voltage) is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2110 Fuel Level Sensor: Service and Repair REMOVAL Fig. 7 Fuel Gauge Sending Unit Location - Typical Module The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module. The fuel pump module is located inside of fuel tank. 1. Remove fuel tank. 2. Remove fuel pump module. 3. Unplug 4-way electrical connector. 4. Disconnect 2 sending unit wires at 4-way connector. The locking collar of connector must be removed before wires can be released from connector. Note location of wires within 4-way connector. Fig. 8 Fuel Gauge Sending Unit Lock Tab/Tracks Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2111 5. The sending unit is retained to pump module with a small lock tab and notch. Carefully push lock tab to the side and away from notch while sliding sending unit downward on tracks for removal. Note wire routing while removing unit from module. INSTALLATION The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module. The fuel pump module is located inside of fuel tank. 1. Position sending unit into tracks. Note wire routing. 2. Push unit on tracks until lock tab snaps into notch. 3. Connect 2 sending unit wires into 4-way connector and install locking collar. 4. Connect 4-way electrical connector to module. 5. Install fuel pump module. 6. Install fuel tank. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications Intake Air Temperature (IAT) Sensor: Specifications Intake Manifold Air TEMP. Sensor ........................................................................................................................................................ 28 Nm (20 Ft. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2115 Intake Air Temperature (IAT) Sensor: Locations Fig. 24 Intake Manifold Air Sensor Location The Intake Manifold Air Temperature (IAT) sensor is installed into the intake manifold plenum near the left side of the throttle body. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2116 Intake Air Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2117 Intake Air Temperature (IAT) Sensor: Description and Operation The 2-wire Intake Manifold Air Temperature (IAT) sensor is installed in the intake manifold with the sensor element extending into the air stream. The IAT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as intake manifold temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. The IAT sensor provides an input voltage to the Powertrain Control Module (PCM) indicating the density of the air entering the intake manifold based upon intake manifold temperature. At key-ON, a 5-volt power circuit is supplied to the sensor from the PCM. The sensor is grounded at the PCM through a low-noise, sensor-return circuit. The PCM uses this input to calculate the following: - Injector pulse-width - Adjustment of spark timing (to help prevent spark knock with high intake manifold air-charge temperatures) The resistance values of the IAT sensor is the same as for the Engine Coolant Temperature (ECT) sensor. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2118 Intake Air Temperature (IAT) Sensor: Service and Repair Fig. 24 Intake Manifold Air Sensor Location REMOVAL The Intake Manifold Air Temperature (IAT) sensor is installed into the intake manifold plenum near the left side of the throttle body. 1. Disconnect electrical connector from sensor. 2. Remove sensor from intake manifold. INSTALLATION 1. Install sensor into intake manifold. Tighten sensor to 28 Nm (20 ft. lbs.) torque. 2. Connect electrical connector to sensor. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications Manifold Absolute Pressure (MAP) Sensor: Specifications MAP Sensor Mounting Screws ............................................................................................................ ..................................................... 3 Nm (25 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2122 Manifold Absolute Pressure (MAP) Sensor: Locations Fig. 27 MAP And ECT Sensor Locations The MAP sensor is located on the front of the intake manifold. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2123 Manifold Absolute Pressure Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2124 Manifold Absolute Pressure (MAP) Sensor: Description and Operation The MAP sensor is located on the front of the intake manifold. An O-ring seals the sensor to the intake manifold. The MAP sensor is used as an input to the Powertrain Control Module (PCM). It contains a silicon based sensing unit to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When manifold absolute pressure (MAP) equals Barometric pressure, the pulse width will be at maximum. A 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5V and full scale is 4.5V. For a pressure swing of 0-15 psi, the voltage changes 4.0V To operate the sensor, it is supplied a regulated 4.8 to 5.1 volts. Ground is provided through the low-noise, sensor return circuit at the PCM. The MAP sensor input is the number one contributor to fuel injector pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or at a higher altitude, because the air density changes with altitude. It will also help to correct for varying barometric pressure. Barometric pressure and altitude have a direct inverse correlation; as altitude goes up, barometric goes down. At key-ON, the PCM powers up and looks at MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure (relative to altitude). Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key-on. The difference between current voltage and what it was at key-on, is manifold vacuum. During key-ON (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring a known good sensor. As the altitude increases, the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key-ON, the barometric pressure needs to be updated. Any time the PCM sees Wide Open Throttle (WOT), based upon Throttle Position Sensor (TPS) angle and RPM, it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor input to aid in calculating the following: - Manifold pressure - Barometric pressure - Engine load - Injector pulse-width - Spark-advance programs - Shift-point strategies (certain automatic transmissions only) - Idle speed - Decel fuel shutoff The MAP sensor signal is provided from a single piezoresistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As manifold pressure changes, the diaphragm moves causing the element to deflect, which stresses the silicone. When silicone is exposed to stress, its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally. The sensor also contains electronics that condition the signal and provide temperature compensation. The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; meaning as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg. Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is approximately 29.92 in Hg. For every 100 feet of altitude, barometric pressure drops 0.10 in. Hg. If a storm goes through it can change barometric pressure from what should be present for that altitude. You should know what the average pressure and corresponding barometric pressure is for your area. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2125 Manifold Absolute Pressure (MAP) Sensor: Service and Repair Fig. 27 MAP And ECT Sensor Locations REMOVAL The MAP sensor is located on the front of the intake manifold. An O-ring seals the sensor to the intake manifold. 1. Disconnect electrical connector at sensor. 2. Clean area around MAP sensor. 3. Remove 2 sensor mounting bolts. 4. Remove MAP sensor from intake manifold. INSTALLATION The MAP sensor is located on the front of the intake manifold. An O-ring seals the sensor to the intake manifold. 1. Clean MAP sensor mounting hole at intake manifold. 2. Check MAP sensor O-ring seal for cuts or tears. 3. Position sensor into manifold. 4. Install MAP sensor mounting bolts (screws). Tighten screws to 3 Nm (25 In. lbs.) torque. 5. Connect electrical connector. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams Engine Oil Pressure Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 2129 Oil Pressure Sensor: Description and Operation DESCRIPTION The 2-wire, electrical/mechanical engine oil pressure sensor (sending unit) is located in an engine oil pressure gallery. OPERATION The oil pressure sensor uses two circuits. They are: ^ A signal to the PCM relating to engine oil pressure ^ A sensor ground through the PCM's sensor return The oil pressure sensor returns a voltage signal back to the PCM relating to engine oil pressure. This signal is then transferred (bussed) to the instrument panel on a CCD bus circuit to operate the oil pressure gauge and the check gauges lamp. Ground for the sensor is provided by the PCM through a low noise sensor return. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 2130 Oil Pressure Sensor: Service and Repair REMOVAL 1. Disconnect the negative cable from the battery. 2. Raise vehicle on hoist. 3. Remove front splash shield. 4. Disconnect oil pressure sender wire (Fig. 107). 5. Remove the pressure sender (Fig. 107). INSTALLATION 1. Install oil pressure sender. 2. Connect oil pressure sender wire. 3. Install front splash shield. 4. Lower vehicle. 5. Connect the negative battery cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Oxygen Sensor .................................................................................................................................... .................................................... 30 Nm (22 Ft. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System Oxygen Sensor: Locations Engine Compartment/Exhaust System The upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. The right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System > Page 2136 Oxygen Sensor: Locations OBD-II Heated Oxygen Sensor Numbering Convention - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2137 Oxygen Sensor: Diagrams Oxygen Sensor 1/1 Upstream (California) Oxygen Sensor 1/2 Downstream (California) Oxygen Sensor 1/2 Downstream (Except California) Oxygen Sensor 2/1 Upstream (California) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2138 Oxygen Sensor 2/2 Downstream (California) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2139 Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2140 Oxygen Sensor Downstream Heater Relay (California) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2141 Oxygen Sensor: Service Precautions WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Application O(2) Sensor Configuration Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Application > Page 2144 Oxygen Sensor: Application and ID OBD-II Heated Oxygen Sensor Numbering Convention - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 2145 Oxygen Sensor: Description and Operation The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Depending on the emission package, the vehicle may use a total of either 2 or 4 sensors. NAA Emissions Package: Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2). With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. NAS or NAE Emissions Package: On this emissions package, 4 sensors are used: 2 upstream (referred to as 1/1 and 2/1) and 2 downstream (referred to as 1/2 and 2/2). With this emission package, the right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. An O2 sensor is a galvanic battery that provides the PCM with a voltage signal (0-1 volt) inversely proportional to the amount of oxygen in the exhaust. In other words, if the oxygen content is low, the voltage output is high; if the oxygen content is high the output voltage is low. The PCM uses this information to adjust injector pulse-width to achieve the 14.7-to-1 air/fuel ratio necessary for proper engine operation and to control emissions. The O2 sensor must have a source of oxygen from outside of the exhaust stream for comparison. Current O2 sensors receive their fresh oxygen (outside air) supply through the wire harness. This is why it is important to never solder an O2 sensor connector, or pack the connector with grease. Four wires (circuits) are used on each O2 sensor: a 12-volt feed circuit for the sensor heating element; a ground circuit for the heater element; a low-noise sensor return circuit to the PCM, and an input circuit from the sensor back to the PCM to detect sensor operation. Oxygen Sensor Heater Relay: If the vehicle is equipped with 4 oxygen sensors, a separate oxygen sensor relay is used to supply voltage to the sensor heating elements. This particular relay is used only for the 1/2 and 2/2 downstream sensors. Voltage for the other 2 sensor heating elements is supplied directly from the ASD relay. To avoid the large simultaneous current surge needed to operate all 4 sensors, power is delayed to the 2 downstream heater elements by the PCM for approximately 2 seconds. Oxygen Sensor Heater Elements: The O2 sensor uses a Positive Thermal Co-efficient (PTC) heater element. As temperature increases, resistance increases. At ambient temperatures around 70 °F, the resistance of the heating element is approximately 13.5 ohms on the this engine. As the sensor's temperature increases, resistance in the heater element increases. This allows the heater to maintain the optimum operating temperature of approximately 930 ° - 1100 °F (500 ° - 600 °C). Although the sensors operate the same, there are physical differences, due to the environment that they operate in, that keep them from being interchangeable. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation, the PCM monitors certain O2 sensor input(s) along with other inputs, and adjusts the injector pulse width accordingly. During Open Loop operation, the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. Upstream Sensor - Engine Equipped With 2 Sensors: The upstream sensor (1/1) provides an input voltage to the PCM. The input tells the PCM the oxygen content of the exhaust gas. The PCM uses this information to fine tune fuel delivery to maintain the correct oxygen content at the downstream oxygen sensor. The PCM will change the air/fuel ratio until the upstream sensor inputs a voltage that the PCM has determined will make the downstream sensor output (oxygen content) correct. The upstream oxygen sensor also provides an input to determine catalytic convertor efficiency. Downstream Sensor - Engine Equipped With 2 Sensors: The downstream oxygen sensor (1/2) is also used to determine the correct air-fuel ratio. As the oxygen content changes at the downstream sensor, the PCM calculates how much air-fuel ratio change is required. The PCM then looks at the upstream oxygen sensor voltage and changes fuel delivery until the upstream sensor voltage changes enough to correct the downstream sensor voltage (oxygen content). The downstream oxygen sensor also provides an input to determine catalytic convertor efficiency. Upstream Sensors - Engine Equipped With 4 Sensors: Two upstream sensors are used (1/1 and 2/1). The 1/1 sensor is the first sensor to receive exhaust gases from the # 1 cylinder. They provide an input voltage to the PCM. The input tells the PCM the oxygen content of the exhaust gas. The PCM uses this information to fine tune fuel delivery to maintain the correct oxygen content at the downstream oxygen sensors. The PCM will change the air/fuel ratio until the upstream sensors input a voltage that the PCM has determined will make the downstream sensors output (oxygen content) correct. The upstream oxygen sensors also provide an input to determine mini-catalyst efficiency. Main catalytic convertor efficiency is not calculated with this package. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 2146 Downstream Sensors - Engine Equipped With 4 Sensors: Two downstream sensors are used (1/2 and 2/2). The downstream sensors are used to determine the correct air-fuel ratio. As the oxygen content changes at the downstream sensor, the PCM calculates how much air-fuel ratio change is required. The PCM then looks at the upstream oxygen sensor voltage, and changes fuel delivery until the upstream sensor voltage changes enough to correct the downstream sensor voltage (oxygen content). The downstream oxygen sensors also provide an input to determine mini-catalyst efficiency. Main catalytic convertor efficiency is not calculated with this package. Engines equipped with either a downstream sensor(s), or a post-catalytic sensor, will monitor catalytic convertor efficiency. If efficiency is below emission standards, the Malfunction Indicator Lamp (MIL) will be illuminated and a Diagnostic Trouble Code (DTC) will be set. Refer to Monitored Systems in Emission Control Systems for additional information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 2147 Oxygen Sensor: Service and Repair REMOVAL Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. For sensor operation, it must have a comparison source of oxygen from outside the exhaust system. This fresh air is supplied to the sensor through its pigtail wiring harness. Fig. 28 Upstream Oxygen Sensor Locations Fig. 29 Downstream Oxygen Sensor Location Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 2148 Fig. 30 Pre-Catalyst/Post-Catalyst Oxygen Sensor Locations Fig. 31 Left/Right Oxygen Sensor Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 2149 Fig. 32 Oxygen Sensor Locations 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 O2S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove the O2S sensor with an oxygen sensor removal and installation tool. 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 O2S sensor. Tighten to 30 Nm (22 ft. lbs.) torque. 2. Connect the O2S sensor wire connector. 3. Lower the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications Power Steering Pressure Switch: Specifications Power Steering Pressure Switch ............................................................................................................................................... 14-22 Nm (124-195 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2153 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2154 Power Steering Pressure Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2155 Power Steering Pressure Switch: Description and Operation DESCRIPTION A pressure sensing switch is included in the power steering system (mounted on the high pressure line). This switch will be used only on vehicles equipped with a 4.7L V-8 engine and power steering. OPERATION The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high pump load and low engine rpm; such as during parking maneuvers. The PCM will then increase the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load. When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the normally closed switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling. When pump pressure drops to approximately 1379 kPa (200 psi), the switch circuit will re-close and engine idle speed will return to its previous setting. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2156 Power Steering Pressure Switch: Service and Repair REMOVAL The power steering pressure switch is installed in the power steering high-pressure hose. 1. Disconnect electrical connector from power steering pressure switch. 2. Place a small container or shop towel beneath switch to collect any excess fluid. 3. Remove switch. Use back-up wrench on power steering line to prevent line bending. INSTALLATION This switch is used only with 4.7L V-8 engine. 1. Install power steering switch into power steering line. 2. Tighten to 14-22 Nm (124-195 inch lbs.) torque. 3. Connect electrical connector to switch. 4. Check power steering fluid and add as necessary. 5. Start engine and again check power steering fluid. Add fluid if necessary. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Mounting Screws ............................................................................................................................................... 7 Nm (60 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2160 Throttle Position Sensor: Locations The TPS is located on the throttle body. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2161 Throttle Position Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2162 Throttle Position Sensor: Description and Operation The 3-wire Throttle Position Sensor (TPS) is mounted on the throttle body and is connected to the throttle blade. The TPS is a 3-wire variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance (output voltage) of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from 0.26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: - Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - OFF-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2163 Throttle Position Sensor: Service and Repair REMOVAL The TPS is located on the throttle body. 1. Remove air duct and air resonator box at throttle body. Fig. 35 Throttle Body, Sensor And Electrical Connectors 2. Disconnect TPS electrical connector. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2164 Fig. 41 TPS Mounting Bolts 3. Remove two TPS mounting bolts (screws). 4. Remove TPS from throttle body. Fig. 43 TPS Installation Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2165 INSTALLATION The throttle shaft end of throttle body slides into a socket in TPS. The TPS must be installed so that it can be rotated a few degrees. If sensor will not rotate, install sensor with throttle shaft on other side of socket tangs. The TPS will be under slight tension when rotated. 1. Install TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 In. lbs.) torque. 3. Manually operate throttle control lever by hand to check for any binding of TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct/air box to throttle body. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Transmission Position Switch/Sensor: Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2169 Transmission Position Switch/Sensor: Description and Operation DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has six switch contacts that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. - Supply ground to the TCM for backup lamp control in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2175 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2176 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2177 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2178 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2179 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2180 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2181 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2182 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2183 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2184 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2185 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2186 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2187 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2188 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2189 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2190 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2191 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2192 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Mounting Screws ............................................................................................................................................... 7 Nm (60 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2197 Throttle Position Sensor: Locations The TPS is located on the throttle body. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2198 Throttle Position Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2199 Throttle Position Sensor: Description and Operation The 3-wire Throttle Position Sensor (TPS) is mounted on the throttle body and is connected to the throttle blade. The TPS is a 3-wire variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance (output voltage) of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from 0.26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: - Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - OFF-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2200 Throttle Position Sensor: Service and Repair REMOVAL The TPS is located on the throttle body. 1. Remove air duct and air resonator box at throttle body. Fig. 35 Throttle Body, Sensor And Electrical Connectors 2. Disconnect TPS electrical connector. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2201 Fig. 41 TPS Mounting Bolts 3. Remove two TPS mounting bolts (screws). 4. Remove TPS from throttle body. Fig. 43 TPS Installation Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2202 INSTALLATION The throttle shaft end of throttle body slides into a socket in TPS. The TPS must be installed so that it can be rotated a few degrees. If sensor will not rotate, install sensor with throttle shaft on other side of socket tangs. The TPS will be under slight tension when rotated. 1. Install TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 In. lbs.) torque. 3. Manually operate throttle control lever by hand to check for any binding of TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct/air box to throttle body. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor ................................................................................................................... ................................................... 12 Nm (106 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2207 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2208 Camshaft Position Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2209 Camshaft Position Sensor: Description and Operation Fig. 4 CMP Location The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. Fig. 5 CMP Sensor And Tonewheel The CMP sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects notches located on a tonewheel. The tonewheel is located at the front of the camshaft for the right cylinder head. As the tonewheel rotates, the notches pass through the sync signal generator. The pattern of the notches (viewed counter-clockwise from front of engine) is: 1 notch, 2 notches, 3 notches, 3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2210 notches, 2 notches 1 notch, 3 notches and 1 notch. The signal from the CMP sensor 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2211 Camshaft Position Sensor: Service and Repair Fig. 7 CMP Location REMOVAL The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. It is easier to remove/install sensor from under vehicle. 1. Raise and support vehicle. 2. Disconnect electrical connector at CMP sensor. 3. Remove sensor mounting bolt. 4. Carefully pry sensor from cylinder head in a rocking action with two small screwdrivers. 5. Check condition of sensor O-ring. INSTALLATION The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. 1. Clean out machined hole in cylinder head. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into cylinder head with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder head. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in. lbs.) torque. 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt .............................................................................................................................................................. 28 Nm (21 Ft. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2215 Crankshaft Position Sensor: Locations Fig. 15 CKP Sensor Location The Crankshaft Position (CKP) sensor is located at the right-rear side of the engine cylinder block. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2216 Crankshaft Position Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2217 Crankshaft Position Sensor: Description and Operation Fig. 15 CKP Sensor Location The Crankshaft Position Sensor (CKP) is mounted into the right-rear side of the engine block. 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. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. Fig. 17 CKP Sensor Operation And Tonewheel Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2218 On this engine, a tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2219 Crankshaft Position Sensor: Service and Repair Fig. 19 CKP Sensor Location/Removal/Installation REMOVAL The Crankshaft Position (CKP) sensor is located at the right-rear side of the engine cylinder block. It is positioned and bolted into a machined hole in the engine block. 1. Disconnect CKP electrical connector at sensor. 2. Remove CKP mounting bolt. 3. Carefully pry sensor from cylinder block in a rocking action with two small screwdrivers. 4. Remove sensor from vehicle. 5. Check condition of sensor O-ring. INSTALLATION 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into engine block with a slight rocking action. Do not twist sensor into position as damage to O-ring may result CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 28 Nm (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL Housing removal is not necessary for element (filter) replacement. 1. Pry up spring clips from housing cover (spring clips retain cover to housing). 2. Release housing cover from locating tabs on housing (Fig. 11) and remove cover. 3. Remove air cleaner element (filter) from housing. 4. Clean inside of housing before replacing element. INSTALLATION 1. Install element into housing. 2. Position housing cover into housing locating tabs. 3. Pry up spring clips and lock cover to housing. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions 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 °C (1000 °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. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2236 Fuel Pressure Release: Service and Repair Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator Clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications ENGINE FIRING ORDER - 4.7L V-8 4.7L ENGINE DESCRIPTION Fig. 1 The 4.7 liter (287 CID) eight-cylinder engine is an 90° single overhead camshaft engine. The cast iron cylinder block is made up of two different components; the first component is the cylinder bore and upper block, the second component is the bedplate that comprises the lower portion of the cylinder block and houses the lower half of the crankshaft main bearings. The cylinders are numbered from front to rear with the left bank being numbered 1,3,5 and 7, and the right bank being numbered 2,4,6 and 8. The firing order is 1-8-4-3-6-5-7-2. The engine serial number is located at the Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 2241 right front side of the engine block (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 2242 Firing Order - 4.7L V-8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Firing Order - 4.7L V-8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Specifications Distributor: Specifications Distributor Holddown Bolt .................................................................................................................... .................................................. 23 Nm (17 Ft. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Specifications > Page 2250 Distributor: Service Precautions WARNING: WHEN PERFORMING THE FOLLOWING TEST, THE ENGINE WILL BE RUNNING. BE CAREFUL NOT TO STAND IN LINE WITH THE FAN BLADES OR FAN BELT. DO NOT WEAR LOOSE CLOTHING. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Plug Gap .............................................................................................................................................. .................................................... 1.01 mm (0.040 in.) Tightening Torque ............................................................................................................................... ...................................................... 27 Nm (20 ft. lbs.) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2254 Spark Plug: Locations The spark plug is located under each ignition coil. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2255 Spark Plug: Application and ID Plug Type ............................................................................................................................................ ............................................................... RC12MCC4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2256 Spark Plug: Description and Operation This engine are equipped with "fired in suppressor seal" type spark plugs using a copper core ground electrode. Because of the use of an aluminum cylinder head on this engine, spark plug torque is very critical. To prevent possible pre-ignition and/or mechanical engine damage, the correct type/heat range/number spark plug must be used. 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 intervals recommended in Lubrication and Maintenance. Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or oil fouled. Also refer to Spark Plug Conditions. 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2257 Spark Plug: Testing and Inspection SPARK PLUG CONDITIONS Fig. 20 Normal Operation And Cold (Carbon) Fouling Normal Operating 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. On this engine gap growth will not average more than approximately 0.0015 in per 3200 km (2000 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 may be affected by MMT deposits. Cold Fouling/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 cleaner element or repeated short operating times (short trips). 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2258 Fig. 21 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. Fig. 22 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2259 Fig. 23 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 fuses. 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. Fig. 24 Chipped Electrode 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2260 Fig. 25 Preignition Damage 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.) Fig. 26 Spark Plug 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 2000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions can also cause spark plug overheating. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2261 Spark Plug: Service and Repair REMOVAL 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. In this engine: Each individual spark plug is located under each ignition coil. Each individual ignition coil must be removed to gain access to each spark plug. Refer to Ignition Coil Removal/Installation. 1. In this engine: Prior to removing spark plug, spray compressed air around base of ignition coil at cylinder head. This will help prevent foreign material from entering combustion chamber. 2. Remove spark plug from cylinder head using a quality socket with a rubber or foam insert. If equipped with this engine, also check condition of coil O-ring and replace as necessary. 3. Inspect spark plug condition. Refer to Spark Plug Conditions. CLEANING The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean spark plugs. Metallic deposits will remain on spark plug insulator and will cause plug misfire. INSTALLATION CAUTION: This engine is equipped with copper core ground electrode spark plugs. They must be replaced with the same type/number spark plug as the original. If another spark plug is substituted, pre-ignition will result. 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. 1. Start the spark plug into the cylinder head by hand to avoid cross threading. 2. In this engine: Tighten spark plugs to 27 Nm (20 ft. lbs.) torque. 3. In this engine: Before installing coil(s), check condition of coil O-ring and replace as necessary. To aid in coil installation, apply silicone to coil O-ring. 4. In this engine: Install ignition coil(s). Refer to Ignition Coil Removal/Installation. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications CYLINDER COMPRESSION PRESSURE RANGE: Compression Pressure ........................................................................................................................ ............................................................... 140 - 180 psi Maximum Allowable Variance Between Cylinders ....................................................................................................................................................... 25 % Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2265 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Secure the throttle in the wide-open position. 4. Disable the fuel system. 5. Remove the ASD relay. 6. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. 7. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders. 8. Refer to SPECIFICATIONS for the correct engine compression pressures. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications Intake Air Temperature (IAT) Sensor: Specifications Intake Manifold Air TEMP. Sensor ........................................................................................................................................................ 28 Nm (20 Ft. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2273 Intake Air Temperature (IAT) Sensor: Locations Fig. 24 Intake Manifold Air Sensor Location The Intake Manifold Air Temperature (IAT) sensor is installed into the intake manifold plenum near the left side of the throttle body. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2274 Intake Air Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2275 Intake Air Temperature (IAT) Sensor: Description and Operation The 2-wire Intake Manifold Air Temperature (IAT) sensor is installed in the intake manifold with the sensor element extending into the air stream. The IAT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as intake manifold temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. The IAT sensor provides an input voltage to the Powertrain Control Module (PCM) indicating the density of the air entering the intake manifold based upon intake manifold temperature. At key-ON, a 5-volt power circuit is supplied to the sensor from the PCM. The sensor is grounded at the PCM through a low-noise, sensor-return circuit. The PCM uses this input to calculate the following: - Injector pulse-width - Adjustment of spark timing (to help prevent spark knock with high intake manifold air-charge temperatures) The resistance values of the IAT sensor is the same as for the Engine Coolant Temperature (ECT) sensor. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2276 Intake Air Temperature (IAT) Sensor: Service and Repair Fig. 24 Intake Manifold Air Sensor Location REMOVAL The Intake Manifold Air Temperature (IAT) sensor is installed into the intake manifold plenum near the left side of the throttle body. 1. Disconnect electrical connector from sensor. 2. Remove sensor from intake manifold. INSTALLATION 1. Install sensor into intake manifold. Tighten sensor to 28 Nm (20 ft. lbs.) torque. 2. Connect electrical connector to sensor. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Fig. 1 Battery Temperature Sensor Location The battery temperature sensor is located under vehicle battery and is attached to a mounting hole on battery tray. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2280 Battery Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2281 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and 02 sensor heater tests). Most OBD II monitors are disabled below 20 degrees F. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2282 Battery Temperature Sensor: Testing and Inspection Tests 1 - 2 SYMPTOM CHECKING THE AMBIENT/BATTERY TEMPERATURE SENSOR POSSIBLE CAUSES - Ambient/Battery temperature sensor - Ambient/Battery temperature sensor (Out Of Calibration) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2283 Battery Temperature Sensor: Service and Repair Fig. 1 Battery Temperature Sensor Location REMOVAL The battery temperature sensor is located under vehicle battery (Fig. 1) and is attached to a mounting hole on battery tray. 1. Remove battery. Refer to Battery for procedures. 2. Disconnect sensor pigtail harness from engine wire harness. Sensor pigtail harness is clipped to vehicle near its electrical connector. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION The battery temperature sensor is located under vehicle battery (Fig. 1) and is attached to a mounting hole on battery tray. 1. Feed pigtail harness through hole in top of battery tray and press sensor into top of battery tray. 2. Connect pigtail harness. 3. Install battery. Refer to Battery for procedures. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions Central Timer Module: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2288 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2289 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2290 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2291 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2292 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2293 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2294 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2295 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2296 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2297 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2298 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2299 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2300 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2301 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2302 Central Timer Module: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2303 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2304 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2305 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2306 Central Timer Module: Electrical Diagrams 8w-45-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2307 8w-45-3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2308 8w-45-4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2309 8w-45-5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2310 8w-45-6 (Base) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2311 8w-45-7 (Light Package) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2312 8w-45-8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2313 8w-45-9 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2314 8w-45-10 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2315 8w-45-11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2316 8w-45-12 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2317 8w-45-13 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2318 8w-45-14 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2319 8w-45-15 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information Central Timer Module: Technician Safety Information WARNING: - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. 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. - NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information > Page 2322 Central Timer Module: Vehicle Damage Warnings Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. 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, Road Testing A Complaint Vehicle Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE REASSEMBLED. DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB III SCREEN WHILE IN MOTION. DO NOT HANG THE DRB III FROM THE REAR VIEW MIRROR OR OPERATE IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB III. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description Central Timer Module: Description and Operation Sytem Description The body system on the 2001 DN consists of a combination of modules that communicate over the PCI bus (Programmable Communication Interface multiplex system). Through the PCI bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all information to perform its function. It will only respond to messages "addressed" to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. All of the information about the functioning of all the systems is organized, controlled, and communicated by the PCI bus, which is described in the vehicle communication of this general information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 2325 Central Timer Module: Description and Operation Functional Operation Part 1 of 2 For additional information on the Base CTM refer to Instrument Panel, Gauges and Warning Indicators / Audible Warning Device. See: Instrument Panel, Gauges and Warning Indicators/Audible Warning Device AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. The Airbag Control Module (ACM) is an electronic module that monitors the airbag system for proper operation, stores diagnostic trouble code (DTCs), controls the airbag warning lamp and contains the sensor and actuator that is responsible for airbag deployment. There are no external impact sensors. The ACM is mounted on a special bracket that is fastened to the floor of the truck at the bottom of the instrument panel. It is located forward of the console. The ACM provides diagnostic information (DTCs) to the technician through the DRB III via the PCI bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp is driven with messages relayed to the Electro/Mechanical Instrument Cluster (EMIC) from the ACM via the PCI bus. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Whenever the ignition key is turned to the "run" or "start" position, the airbag control module performs a lamp check by turning the AIRBAG warning lamp ON for 6 - 8 seconds. If the lamp remains OFF, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains ON, there could be an active fault in the system or the circuit that operates the lamp may be shorted to ground. If the lamp comes ON and stays ON for a period longer than 6 - 8 seconds, then goes OFF, there is usually an intermittent problem in the system. WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. 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. - NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. Seat Belt Tensioner Front seat belt systems incorporate Tensioner Modules (SBT). At the onset of an impact event each tensioner uses a pyrotechnic device, which is triggered simultaneously with the airbags, to rapidly retract the seat belts. With the slack removed, the occupant's forward motion in an impact will be reduced as will the likelihood of contacting interior components. After an impact that deploys the airbag, the seat belt tensioner assembly must be replaced. The ACM module monitors the Seat Belt Tensioners circuit resistance and reports active and stored DTC's if any problem is found. Airbag Diagnostic Trouble Codes Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB III. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures, diagnostic trouble codes are used as a diagnostic tool. Active Codes The code becomes active as soon as the malfunction is detected and stored after one minute of occurrence or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 2326 of 12 seconds or as long as the malfunction is present. Stored Codes Airbag codes are automatically stored in the ACM's memory after one minute of occurrence or when the ignition is turned OFF. The exception is the "Loss of Ignition Run Only" code which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored as long as the malfunction exists. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, that diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "ON" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. AUDIO SYSTEM The factory installed radio receiver communicates on the Programmable Communication Interface (PCI) data bus network through a separate two-way wire harness connector. This is used for the remote radio switches that are mounted to the steering wheel, and also used for radio diagnosis with the DRB III. The remote radio switches are resistor multiplexed units that are hard wired to the CTM through the clockspring. The CTM monitors the status of the remote radio switches and sends the proper switch status messages on the PCI data bus network to the radio receiver. The electronic circuitry within the radio is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. When troubleshooting output shorts or "output" error messages, the following applies: On radios without an external amplifier, the term "output" refers to the path between the radio and the speaker. This type of circuit can be monitored all the way through the speaker connections by the radio assembly. When the radio displays a shorted output DTC with this type of system, the speaker, radio or wiring could be at fault. The output DTC could refer to a front or rear output or a left or right output. The reason for the difference is the pairing of the output sections of the radio. Some are paired left and right, others are paired front and rear. On radios with an external amplifier, the term "output" refers to the circuit between the radio connector and the amplifier. The radio is capable of monitoring only this portion and can tell nothing about the circuit between the amplifier and the speakers. Consequently, a shorted output DTC on this type of system would only refer to this circuit. A faulty speaker could not cause this DTC. CENTRAL TIMER MODULE The Durango (DN) utilizes a Central Timer Module (CTM). This system is available in a Base or Highline configuration. The CTM performs most of the typical functions a Body Control Module would perform. The Base and Highline CTM provides the following features: Battery Saver Functions For Exterior and Interior Lamps - Cargo Lamps - Chime Warning - Courtesy Lamps - Dome Lamps - Dome Defeat - Door Ajar Switch Status - Fog Lamps - Head Lamp Time Delay - Intermittent Wiper Controls - Low and High Beam Head Lamps - Optical Horn - Park Lamps Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 2327 Additional features of Highline CTM Central Locking (VTSS) - Door Lock Inhibit - Driver Door Unlock - Enhanced Accident Response - Power Door Locks - Remote Radio - Remote Keyless Entry - Vehicle Theft Alarm (VTSS) The Central Timer Module is located behind the left side kick panel. It contains 26-way, 16-way and 12-way connectors. CHIME SYSTEM The chime system is built into the CTM. There are two chime rates, Low: 50 chimes per minute for reminders and High: 180 chimes per minute for serious conditions that require immediate attention. The high rate chime sounds when the key is left in the ignition and the driver's door is open or if the headlights or the courtesy lights are left on. The low rate chime sounds for any of the other conditions. There is a variable rate feature that allows the chime to sound continuously for key-in and headlamp warning as long as the door is open. The seat belt warning chime is activated for six seconds, and all other chime conditions will activate the chime once at the same time the warning light on the cluster is illuminated. The Chime will sound for the following conditions: Ignition OFF key in ignition, driver's door open - Ignition OFF, headlamps ON, driver's door open - Ignition OFF, courtesy lamps ON, driver's door open - Seat belt warning (after prove-out) - Malfunction Indicator lamp (MIL) illuminated (after prove-out) - Airbag lamp illuminated (after prove-out) - Check gauges lamp - Low fuel warning - Low washer fluid lamp - Door ajar warning - Transmission temperature lamp - Turn signal on reminder warning - Button pushed on compass mini-trip computer COMPASS MINI-TRIP COMPUTER (CMTC) This system, located in the overhead console, displays information on outside temperature, compass direction and trip information. Compass and Temperature Display This display provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. Trip Odometer (ODO) Shows the distance traveled since the last reset. Average Fuel Economy (AVE ECO) Shows the average fuel economy in MPG (miles per gallon) or L/100 Km since the last reset. Instant Fuel Economy Shows the fuel economy for the last few seconds in MPG or L/100 Km. Distance to Empty (DTE) Shows the estimated distance that can be traveled with the fuel remaining in the tank. This is calibrated using the MPG for the last few minutes. Elapsed Time (ET) Shows the accumulated ignition ON time since the last reset. Step Button Press this button to cycle through all the mini-trip computer displays. US/M Button Press this button to convert all vehicle displays from US to Metric to US. To Reset the Display Press the Step and US/M buttons simultaneously for at least two seconds and all resettable conditions will be reset. This will occur only if a resettable function (AVG ECO, ECO, ET) is currently being displayed. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 2328 Automatic Compass Calibration This compass is self calibrating which eliminates the need to manually set the compass. When the vehicle is new, the compass may appear erratic and the CAL symbol will be displayed. After completing three 360' turns in an area free from large metal or metallic objects, the CAL symbol will turn OFF and the compass will function normally. Compass Variance Compass Variance is the difference between Magnetic North and Geographic North. In some areas of the country, the difference between Magnetic and Geographic North is great enough to cause the compass to give false readings. If this occurs, the compass variance must be set. To Set the Variance Turn the ignition ON and set display to Comp./Temp. while pressing the US/M button, press the STEP button for approximately five seconds. The "VAR" symbol will light and the last variance zone number will be displayed. Press the US/Metric Button to select the proper variance zone as shown on the map. Press the Step button to set the new variance zone and resume normal operation. ELECTRO/MECHANICAL INSTRUMENT CLUSTER (EMIC) The Instrument Cluster contains a Fuel, Voltmeter, Coolant Temp, and Oil Pressure gauge, a Tachometer and a Speedometer. With the exception of the Voltmeter, the cluster positions the gauges with PCI Bus messages received from the PCM. The Voltmeter operates directly off of the Fused B+ Switched Ignition Output circuit that supplies ignition voltage for the cluster. The Instrument Cluster also contains warning indicators that are illuminated by hard wired inputs or by messages received from other modules on the PCI Bus. The Trip/Total Odometer is a Vacuum Fluorescent Display (VF) that is controlled by PCI Bus messages received from the PCM. The cluster illumination lamps are hard wired in the Instrument Cluster. When the Park or Headlamps are turned ON, the cluster receives a dimmed battery feed from the Headlamp Switch. The cluster I/O Processor controls the VF display dimming and also sends dimming level messages on the PCI Bus. The EMIC will communicate with the DRB III to display PCI Engine Info, PCI Bus Info, and certain input/outputs. Cluster diagnostic capabilities that the DRB III will actuate are limited to the Cluster Calibration Points for the gauges. The DRB III can also extract active and stored Diagnostic Trouble Codes (DTC) from the Instrument Cluster. The EMIC is also capable of performing a diagnostic Self-Test that is actuated by depressing and holding the Odometer trip reset stalk while cycling the ignition from the OFF to the ON position. After the cluster Odometer displays CHEC, releasing the reset stalk begins the test. The cluster will then position all of the gauges at specified calibration points and will illuminate all the PCI Bus controlled indicators. The cluster will also illuminate each segment of the VF display. The EMIC can verify communications with the PCM, ID the module, or change the country code using the DRB III. ENHANCED ACCIDENT RESPONSE (HIGHLINE CTM ONLY) If the Airbag Control Module (ACM) deploys the airbags, a message is transmitted over the PCI bus to the CTM module to unlock the doors. The interior lights will be turned ON when the vehicle speed message on the PCI bus indicates 0 mph or the message is not present. In addition to unlocking the doors, the door lock feature will be disabled for a predetermined amount of time following the deployment. Once the ignition key has been cycled to the "OFF" position, normal operation will resume. EXTERIOR LIGHTING The low and high beam headlamps are controlled directly by an output from the Central Timer Module (CTM). The park lamps and fog lamps (on vehicle so equipped) are controlled via external relays that are energized by the CTM. The headlamp switch provides the control signal through the multifunction switch to the CTM, which indicates low or high beam operation. The Optical Horn (Flash to Pass) feature operates both the high beam and low beam headlamps. The CTM provides the Headlamp Time Delay feature. To start the delay, turn the ignition OFF while the headlamps are ON. Then turn the headlamp switch to the OFF position. This has to be done within 45 seconds of the ignition being turned OFF. The headlamps will remain ON for 60 ± 5 seconds. If during this delay period the headlamp switch is turned ON and then OFF, or ignition switch is turned ON delay will be canceled and they will turn OFF immediately. During the delay period, only headlamps are turned ON and park lamps/fog lamps are turned OFF. The CTM also provides battery protection to avoid wearing down the battery if the customer leaves the park lamps or headlamps ON for extended period of time with the ignition OFF. If the park lamps or headlamps remain ON for more than 5 minutes while the ignition is OFF, the headlamps and park lamps shall be turned off and the input causing the lamps to be ON will be ignored until the input is corrected. Once the 5 minute timeout has extinguished the headlamps and park lamps, any change in the ignition switch, door ajar switches, headlamps switch or park lamp switch will reset the 5 minute timer and return the headlamps and park lamps to normal operation. Part 2 of 2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 2329 HEATING & A/C SYSTEM The all-new heating and air conditioning system for DN provides more heating and cooling capacity than in previous years. Depending on the model, either a Dual-Zone Air Conditioning System or a Three-Zone Air Conditioning System is currently available in these vehicles. Air Distribution (Front) The front compartment HVAC unit has four fully adjustable instrument panel outlets. Side-window demister outlets in the instrument panel eliminate the need for door ducts and door-to-instrument panel seals. A single central mounted outlet delivers air for defrosting the windshield. Two outlets, one on each side of the center console underneath the instrument panel, provide airflow to the driver floor area and to the front seat passenger floor area. While two additional outlets, one on each side of the center console near the rear of the front seats, distribute both heated and cooled air across the floor to the intermediate seat passengers. Ducts in the center of the vehicle underneath the carpet deliver air from the front compartment HVAC unit to the two intermediate passenger outlets. Door Actuator Control A simplified control system for operation of the mode, recirculation, and temperature control actuators provides positive positioning without the complexity of feedback from position sensors. The A/C - Heater Control Module knows the number of operating actuator revolutions required for full door travel as well as the number of actuator commutator pulses per revolution. Using these parameters, the A/C - Heater Control Module runs the actuator for the number of commutator pulses that correspond to the desired door position. To maintain accuracy, the system recalibrates itself periodically at known zero and full travel conditions. The dual sliding Blend switches have multiple detents to control the full range of temperature that the system can produce in any mode. On Dual-Zone systems, the upper slide pot controls the driver-side blend door and the lower slide pot controls the passenger-side blend door. On Three-Zone systems, the upper slide pot controls the driver-side blend door, while the lower slide pot controls the passenger-side blend door and the rear A/C - heater unit blend door. The single rotary Mode switch has 12 detents to either direct airflow to the panel outlets, to a mix of floor and panel outlets, to the floor outlets, to a mix of floor and defrost outlets, or to the defrost outlet. Rotating the Mode switch to either of the two MAX positions results in the A/C - Heater Control Module sending a signal to the recirculation actuator to close the fresh-air door. While rotating the Mode switch to any other position results in the A/C - Heater Control Module sending a signal to the recirculation actuator to open the fresh-air door. When the Blower switch is OFF, the A/C - Heater Control Module closes the fresh-air door to prevent outside air from entering the vehicle. On Three- Zone systems, the Mode switch also controls the rear A/C - heater unit mode door, which directs rear airflow either to the right quarter trim panel outlet or to the overhead outlets. Front Blower Control The front blower circuitry employs a new resistor technology to control front blower speed. Called the "credit card" resistor, the device looks much like its name in that it is thin and compact like a credit card. The credit card resistor, like the coil resistor used in previous years, mounts inside the front HVAC housing assembly in the airflow path. However, unlike the coil resistor, the credit card resistor offers much less airflow restriction. A/C Operation The A/C - Heater Control Module monitors the temperature of the evaporator to keep it just above freezing for maximum cooling and dehumidification. A thermistor (temperature variable resistor) placed between the evaporator fins provides the signal for the control. The Powertrain Control Module (PCM) cycles the compressor on and off with a signal from the A/C - Heater Control Module. Heater Operation To assist the HVAC system in maintaining a consistent and optimum heat output at low vehicle speeds, an electric coolant pump operates under specific conditions to keep a steady flow of hot coolant circulating through the heater circuit. The A/C - Heater Control Modules controls the operation of the electric coolant pump. The pump runs when all of the following conditions are met: When the vehicle's speed is below 27 Km/h (17 mph), the coolant temperature is between 65.5 °C and 110 °C (150 °F and 230 °F), and the blend control is set above 60% reheat. The A/C - Heater Control Module turns the pump OFF if any one of the following conditions occur: The vehicle speed rises above 48.3 Km/h (30 mph). The coolant temperature drops below 65.5 °C (150 °F). The coolant temperature rises above 110 °C (230 °F). The blend control is set below 60% reheat. A/C - Heater Control (Rear) The Three-Zone system allows the intermediate seat occupants to regulate the air temperature and the fan speed of the rear unit from the rotary controls on the headliner mounted Rear A/C - Heater Control. HVAC Diagnostics The A/C - Heater Control Module is fully addressable with the DRB III. Two of the Control Module's diagnostic capabilities that the DRB III will actuate include the A/C Cool down Test to test A/C system performance and the HVAC Door Recalibration Test to determine actuator travel span. After performing either test, the Control Module will display one or more messages on the DRB III screen. The message will indicate either that the HVAC system passed the test or that there is a fault currently active in the HVAC system. The DRB III can also extract active and stored Diagnostic Trouble Codes (DTCs) from the control module. Active DTCs are faults that currently exit in the HVAC system. Stored DTCs are faults that occurred in the HVAC system since the control module received the last "clear diagnostic info" message. INTERIOR LIGHTING Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 2330 The Courtesy lights and illuminated entry feature are controlled by the Central Timer Module (CTM). The CTM will activate the courtesy lamps, including Map Lights and the Dome Lights when either the dome lamp switch is turned ON or a door is opened. The courtesy lamps will fade to OFF immediately when all doors are closed with the dome lamp switch in the OFF position. The illuminated entry feature operates under the following conditions: RKE "unlock" - Driver/Passenger door is opened - Unlocking either the driver or passenger using the key (vehicles equipped with security system) - The dome lamp switch is turned ON Once activated, the illuminated entry will "fade to OFF" after 3 to 5 seconds under the following conditions: All doors are closed and: RKE "lock signal is received or - Manual actuated power "lock" signal is received or - Ignition switch is turned to the ON position or - 30 seconds have elapsed without any other action Addition RKE unlock actuation before the expiration of illuminated entry will not reset timer. Opening any door before the 30 second timer expires, will reset the entry time to 30 seconds and the illuminated entry timer will not begin counting down again until all doors are closed. The Cargo lamps are controlled by the CTM. Placing the dome lamp switch in the cargo lamp position grounds an input to the CTM. The CTM then sends voltage to the cargo lamps. The Interior lamp defeat feature will not allow any interior lamp to be turned ON. This is accomplished through an input to the CTM from the dome lamp switch. The CTM provides battery protection by shutting down the interior lamps due to the following. Leaving a door open, dome lamp switch ON, reading/vanity lamp switch ON or glove box door open for more than 15 minutes while the ignition is OFF. POWER DOOR LOCKS/REMOTE KEYLESS ENTRY The CTM controls the door lock actuator assemblies to handle locking and unlocking with the key fob or interior switch. Vehicles that are equipped with the Vehicle Theft Security System will also have the central locking feature. With the central locking feature, when the cylinder lock switch is turned to the lock position all the doors will lock. For unlocking, if the key is turned to the unlock position once, only that door will unlock. If the key is then turned a second time to the unlock position, all the doors will unlock. There is also a door lock inhibit feature that prevents power locking of the doors if the ignition is OFF and the key is in the ignition. Automatic or "rolling locks" are included as a programmable feature. If the vehicle is moving approximately 15 mph and approximately 10 degrees of throttle opening is seen by the PCM, (the PCM will send this info to the CTM via the PCI bus) indicating acceleration, the CTM will cycle the lock actuators to lock the doors. The highline CTM provides for Remote Keyless Entry (RKE) The RKE system is placed in the programming mode by the DRB III, or by the customer program features. The system will store up to four key fob codes. Two fobs are supplied with the truck, additional fobs may be purchased through the parts department. Through the DRB III, erasing and programming of one key fob without deleting the others is possible. If the key fob is stolen, all the fob codes stored previously may be erased to provide the owner of the vehicle with an extra sense of security. VEHICLE COMMUNICATION The Programmable Communication Interface or PCI Bus is a single wire multiplexed network capable of supporting binary encoded messages shared between multiple modules. The PCI bus circuit is identified as D25 and is violet with a yellow tracer. Additional tracer colors may be added to the yellow in order to distinguish between different module connections. The modules are wired in parallel. Connections are made in the harness using a splice. The splice called the Diagnostic Junction Port, serves as the "Hub" of the bus. The Diagnostic Junction Port provides an access point to isolate most of the modules on the bus in order to assist in diagnosing the circuit. The following modules are used on the DN: Airbag Control Module - A/C Heater Control - Central Timer Module - Controller Antilock Brake - Compass Mini-Trip Computer - Electro/Mechanical Instrument Cluster - Powertrain Control Module - Radio Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 2331 - Sentry Key Immobilizer Module - Transfer Case Control Module - Transmission Control Module Each module provides its own bias and termination in order to transmit and receive messages. The bus voltage is at zero volts when no modules are transmitting and is pulled up to about seven and a half volts when modules are transmitting. The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRB III lab scope. The 12v square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between zero and about seven and a half volts. Refer to the figure for some typical displays. The PCI Bus failure modes are broken down into two categories. Complete PCI Bus Communication Failure and individual module no response. Causes of complete PCI Bus Communication Failure include a short to ground or battery on the PCI circuit. Individual module no response can be caused by an open circuit at either the Diagnostic Junction Port or the module, or an open battery or ground circuit to the affected module. Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: All gauges on the EMIC stay at zero - All telltales on EMIC illuminate - EMIC backlighting at full intensity - Dashed lines in the Compass Mini-Trip Computer display Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 2332 - No response received from any module on the PCI bus (except the PCM) - No start (if equipped with Sentry Key immobilizer) Symptoms of Individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRB III. Diagnosis starts with symptom identification. If a complete PCI Bus Communication Failure is suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRB III. If any modules are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI circuit or power supply and ground circuits. The DRB III may display "BUS +A SIGNAL OPEN" or "NO RESPONSE" to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRB III and in no way indicates whether or not the PCI bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped. VEHICLE THEFT SECURITY SYSTEM The VTSS system monitors the door ajar switches, and ignition switch to detect unauthorized entry into the vehicle. Once the vehicle is "armed", any one of these inputs can cause the VTSS system to be tripped. Once tripped, the horn and lights will pulse for 3 minutes and if an attempt is made to start the engine with a non-programmed SKIM key, it will start and stall. If the trigger condition is still present, the lights will continue to flash for an additional 15 minutes, after which the system will stop pulsing the lights and return to the "armed" state. The cause of the last 4 alarm triggers is stored by the CTM and may be retrieved by the DRB III. The system may be disarmed by either an unlock command from a valid RKE key fob by using a key in either door, or by using a valid SKIM key in the ignition. The door key cylinders are equipped with disarm switches. There is also a VTSS lamp on the dash that provides information to the driver about the state of the vehicle theft system. WINDSHIELD WIPER SYSTEM The DN truck is equipped with speed sensitive intermittent wipers. The low and high speeds are controlled through the wiper stalk switch. The intermittent portion of the wiper control is handled by the CTM through the intermittent wiper relay. When the module detects a decrease in delay time as selected by the driver, an immediate wipe of the windshield takes place and the new delay interval is implemented. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Central Timer Module: Symptom Related Diagnostic Procedures Non-Trouble Code Procedures For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. The hard wired inputs to and outputs from the Central Timer Module (CTM) may be diagnosed and tested using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the CTM. In order to obtain conclusive testing of the CTM, the Programmable Communications Interface (PCI) data bus network and all of the electronic modules that provide inputs to or receive outputs from the CTM must also be checked. The most reliable, efficient, and accurate means to diagnose the CTM, the PCI data bus network, and the electronic modules that provide inputs to or receive outputs from the CTM requires the use of a DRB III scan tool. Refer to the appropriate diagnostic information. The DRB III scan tool can provide confirmation that the PCI data bus network is functional, that all of the electronic modules are sending and receiving the proper messages over the PCI data bus, and that the CTM is receiving the proper hard wired inputs and responding with the proper hard wired outputs needed to perform its many functions. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: The following tests may not prove conclusive in the diagnosis of the Central Timer Module (CTM). The most reliable, efficient, and accurate means to diagnose the CTM requires the use of a DRB III scan tool. Refer to the appropriate diagnostic information. 1. Check the fused B(+) fuses (Fuse 3 - 20 ampere, and Fuse 12 - 20 ampere) in the Power Distribution Center (PDC). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fused B(+) fuses (Fuse 3 - 20 ampere, and Fuse 12 - 20 ampere) in the PDC. If OK, go to Step 3. If not OK, repair the open B(+) circuit between the PDC and the battery as required. 3. Disconnect and isolate the battery negative cable. Disconnect the instrument panel wire harness connector (Connector C3) for the CTM from the CTM connector receptacle. Reconnect the battery negative cable. Check for battery voltage at each of the two fused B(+) circuit cavities of the instrument panel wire harness connector (Connector C3) for the CTM. If OK, disconnect and isolate the battery negative cable, reconnect the instrument panel wire harness connector (Connector C3) for the CTM to the CTM connector receptacle, and go to Step 4. If not OK, repair the open fused B(+) circuit(s) between the CTM and the PDC as required. 4. Check the fused ignition switch output (run-start) fuse (Fuse 11 - 10 ampere) and the fused ignition switch output (run-acc) fuse (Fuse 5 - 20 ampere) in the Junction Block (JB). If OK, go to Step 5. If not OK, repair the shorted circuit or component as required and replace the faulty fuse(s). 5. Reconnect the battery negative cable. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run-start) fuse (Fuse 11 - 10 ampere) and the fused ignition switch output (run-acc) fuse (Fuse 5 20 ampere) in the JB. If OK, go to Step 6. If not OK, repair the open fused ignition switch output (run-start) circuit or fused ignition switch output (run-acc) circuit between the JB and the ignition switch as required. 6. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the instrument panel wire harness connector (Connector C1) for the CTM from the CTM connector receptacle. Reconnect the battery negative cable. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run-start) circuit cavity and the fused ignition switch output (run-acc) cavity of the instrument panel wire harness connector (Connector C1) for the CTM. If OK, go to Step 7. If not OK, repair the open fused ignition switch output (run-start) circuit or fused ignition switch output (run-acc) circuit between the CTM and the JB as required. 7. Turn the ignition switch to the OFF position. Check for continuity between each of the three ground circuits in the instrument panel wire harness connector (Connector C1) for the CTM and a good ground. In each case there should be continuity. If OK, use a DRB III scan tool to perform further diagnosis of the CTM. Refer to the appropriate diagnostic information. If not OK, repair the open ground circuit(s) to ground (G207 or G208) as required. Chime Inoperative At All Times Test 1 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2335 SYMPTOM CHIME INOPERATIVE AT ALL TIMES POSSIBLE CAUSES - CTM - Chime inoperative Chime Inoperative With Drivers Seat Belt Unfastened Tests 1 - 4 SYMPTOM CHIME INOPERATIVE WITH DRIVER SEAT BELT UNFASTENED POSSIBLE CAUSES - Seat belt switch status wrong - Seat belt switch shorted - Seat belt indicator driver wire short to ground - Instrument cluster - seat belt switch shorted Chime Inoperative With Key In Ignition and Driver's Door Open Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2336 Tests 1 - 4 Test 5 SYMPTOM CHIME INOPERATIVE WITH KEY IN IGNITION, DRIVER'S DOOR OPEN POSSIBLE CAUSES - Driver door ajar status - Ignition switch ground circuit open - Key-in ignition switch open - Key-in ignition switch sense circuit open - Central timer module Chime Inoperative, Exterior/Interior Lamps On, Driver Door Open Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2337 Tests 1 - 2 SYMPTOM CHIME INOPERATIVE WITH EXTERIOR OR INTERIOR LAMPS ON WITH DRIVER DOOR OPEN POSSIBLE CAUSES - DRB check driver door ajar - CTM-chime inoperative with headlamp switch - Operation of exterior or interior lighting system Chime Sounds With Driver Seat Belt Fastened Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2338 Tests 1 - 4 Test 5 SYMPTOM CHIME SOUNDS WITH DRIVER SEAT BELT FASTENED POSSIBLE CAUSES - Seat belt switch status wrong - Seat belt switch open - Ground wire open - Seat belt indicator driver wire open - Instrument cluster - seat belt sense open Chime Sounds With Drivers Door Open and Key Removed From Ignition Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2339 Tests 1 - 4 SYMPTOM CHIME SOUNDS WITH DRIVER'S DOOR OPEN, KEY REMOVED POSSIBLE CAUSES - Operation of exterior or interior lighting system - Key-in ignition switch shorted - Key-in ignition SW sense short to ground - Central timer module - key-in ignition shorted Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2340 Central Timer Module: Component Tests and General Diagnostics Road Testing A Complaint Vehicle ROAD TEST WARNINGS Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the test drive, do not try to read the DRB III screen while in motion. Do not hang the DRB III from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB III. Six Step Troubleshooting Procedure SIX-STEP TROUBLESHOOTING PROCEDURE Diagnosis is done in six basic steps: 1. Verification of complaint 2. Verification of any related symptoms 3. Symptom analysis 4. Problem isolation 5. Repair of isolated problem 6. Verification of proper operation Vehicle Preparation For Testing VEHICLE PREPARATION FOR TESTING Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2341 Central Timer Module: Scan Tool Testing and Procedures DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB III will display one of only two error messages: User-Requested WARM Boot (Press MORE and NO at the same time) User-Requested COLD Boot (Press MORE and YES at the same time) If the DRB III should display any other error message, record the entire display and call the S.T.A.R. Center for information and assistance. DRB III DOES NOT POWER UP If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB III. If all connections are proper between the DRB III and the vehicle or other devices, and the vehicle battery is fully charged, and inoperative DRB III may be the result of faulty cable or vehicle wiring. For a blank screen, refer to the appropriate body diagnostics. DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition SOME DISPLAY ITEMS READ "---" This is caused by scrolling the DRB III display a single line up or down. The line which was scrolled onto the screen might read "---". Use the Page Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2342 Down or Page Up function to display the information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Page 2343 Central Timer Module: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: Before replacing a Central Timer Module (CTM), use a DRB III scan tool to retrieve the current settings for the CTM programmable features. Refer to the appropriate diagnostic information. These settings should be duplicated in the replacement CTM using the DRB III scan tool before returning the vehicle to service. 1. Disconnect and isolate the battery negative cable. 2. Remove the trim from the left cowl side inner panel. Fig. 2 Central Timer Module 3. Disconnect the two instrument panel wire harness connectors and one body wire harness connector from the CTM connector receptacles. 4. Remove the three screws that secure the CTM to the left cowl side inner panel. 5. Remove the CTM from the left cowl side inner panel. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: Before replacing a Central Timer Module (CTM), use a DRB III scan tool to retrieve the current settings for the CTM programmable features. Refer to the appropriate diagnostic information. These settings should be duplicated in the replacement high-line/premium CTM using the DRB III scan tool before returning the vehicle to service. 1. Position the CTM onto the left cowl side inner panel. 2. Install and tighten the three screws that secure the CTM to the left cowl side inner panel. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the two instrument panel wire harness connectors and one body wire harness connector to the CTM connector receptacles. 4. Reinstall the trim onto the left cowl side inner panel. 5. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Page 2344 Central Timer Module: Tools and Equipment DRB III (Diagnostic Read-out Box) Jumper Wires Ohmmeter Voltmeter Test Light Diagnostic Junction Port Tester 8310 Airbag Load Tool 8443 Airbag Load Tool Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Brake Pressure Switch > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor ................................................................................................................... ................................................... 12 Nm (106 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2352 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2353 Camshaft Position Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2354 Camshaft Position Sensor: Description and Operation Fig. 4 CMP Location The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. Fig. 5 CMP Sensor And Tonewheel The CMP sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects notches located on a tonewheel. The tonewheel is located at the front of the camshaft for the right cylinder head. As the tonewheel rotates, the notches pass through the sync signal generator. The pattern of the notches (viewed counter-clockwise from front of engine) is: 1 notch, 2 notches, 3 notches, 3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2355 notches, 2 notches 1 notch, 3 notches and 1 notch. The signal from the CMP sensor 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2356 Camshaft Position Sensor: Service and Repair Fig. 7 CMP Location REMOVAL The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. It is easier to remove/install sensor from under vehicle. 1. Raise and support vehicle. 2. Disconnect electrical connector at CMP sensor. 3. Remove sensor mounting bolt. 4. Carefully pry sensor from cylinder head in a rocking action with two small screwdrivers. 5. Check condition of sensor O-ring. INSTALLATION The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. 1. Clean out machined hole in cylinder head. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into cylinder head with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder head. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in. lbs.) torque. 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications Engine Coolant Temperature (ECT) Sensor: Specifications Engine Coolant Temperature Sensor ....................................................................................................................................................... 11 Nm (96 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2360 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2361 Engine Coolant Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2362 Engine Coolant Temperature (ECT) Sensor: Description and Operation DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: ^ for engine coolant temperature gauge operation through CCD or PCI (J1850) ^ Communications ^ Injector pulse-width ^ Spark-advance curves ^ ASD relay shut-down times ^ Idle Air Control (IAC) motor key-on steps ^ Pulse-width prime-shot during cranking ^ 02 sensor closed loop times ^ Purge solenoid on/off times ^ EGR solenoid on/off times (if equipped) ^ Leak Detection Pump operation (if equipped) ^ Radiator fan relay on/off times (if equipped) ^ Target idle speed Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2363 Engine Coolant Temperature (ECT) Sensor: Service and Repair REMOVAL - 4.7L WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. The ECT sensor is located near the front of the intake manifold. 1. Partially drain cooling system. 2. Disconnect electrical connector from ECT sensor. 3. Remove sensor from intake manifold. INSTALLATION - 4.7L 1. Install sensor. 2. Tighten to 11 Nm (8 ft. lbs.) torque. 3. Connect electrical connector to sensor. 4. Replace any lost engine coolant. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt .............................................................................................................................................................. 28 Nm (21 Ft. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2367 Crankshaft Position Sensor: Locations Fig. 15 CKP Sensor Location The Crankshaft Position (CKP) sensor is located at the right-rear side of the engine cylinder block. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2368 Crankshaft Position Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2369 Crankshaft Position Sensor: Description and Operation Fig. 15 CKP Sensor Location The Crankshaft Position Sensor (CKP) is mounted into the right-rear side of the engine block. 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. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. Fig. 17 CKP Sensor Operation And Tonewheel Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2370 On this engine, a tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2371 Crankshaft Position Sensor: Service and Repair Fig. 19 CKP Sensor Location/Removal/Installation REMOVAL The Crankshaft Position (CKP) sensor is located at the right-rear side of the engine cylinder block. It is positioned and bolted into a machined hole in the engine block. 1. Disconnect CKP electrical connector at sensor. 2. Remove CKP mounting bolt. 3. Carefully pry sensor from cylinder block in a rocking action with two small screwdrivers. 4. Remove sensor from vehicle. 5. Check condition of sensor O-ring. INSTALLATION 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into engine block with a slight rocking action. Do not twist sensor into position as damage to O-ring may result CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 28 Nm (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Data Link Connector: Locations The data link connector is located at the lower edge of the instrument panel near the steering column. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2377 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2378 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2379 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2380 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2381 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2382 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2383 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2384 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2385 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2386 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2387 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2388 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2389 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2390 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2391 Data Link Connector: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2392 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2393 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2394 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2395 Data Link Connector: Connector Views Data Link Connector Data Link Connector Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Page 2396 Data Link Connector: Description and Operation The data link connector is located at the lower edge of the instrument panel near the steering column. The 16-way data link connector (diagnostic scan tool connector) links the Diagnostic Readout Box (DRB) scan tool or the Mopar Diagnostic System (MDS) with the Powertrain Control Module (PCM). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts Powertrain Control Module: Customer Interest A/T - 45RFE/545RFE Harsh Upshifts/Downshifts NUMBER: 18-025-01 GROUP: Vehicle Performance DATE: October 15, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-09-00, DATED SEPTEMBER 15, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. **ASTERISKS** HAVE BEEN USED TO HIGHLIGHT CHANGES. THIS BULLETIN ADDS A MODEL YEAR AND REQUIRES A REPROGRAMMING OF THE 1999 AND 2000 GRAND CHEROKEE POWERTRAIN CONTROL MODULE (PCM). SUBJECT: 45RFE **and 545RFE Shift** Quality Enhancements for the** 2-3, 4-5, and 5-4** Shifts OVERVIEW: This bulletin involves selectively erasing and reprogramming the **Transmission Control Module (TCM) with new software: '99-'01 WJ (PN 05019701AC Ver 9.3), '00 AN/DN (PN 05018454AB Ver 9.1), or '01 AN/DN (PN 56028285A1 Ver 8.4), and requires reprogramming of the Powertrain Control Module (PCM) for the 1999 and 2000 Grand Cherokees only (with calibration 99Cal20 (1999) or 00Cal17 (2000).** NOTE: THE 2001 GRAND CHEROKEE DOES NOT REQUIRE REPROGRAMMING OF THE PCM AS IT IS ALREADY AT THE CORRECT CALIBRATION LEVEL. NOTE: WHENEVER A PCM OR TCM IS REPLACED OR REPROGRAMMED, THE SOFTWARE OF THE PCM MUST BE VERIFIED AS HAVING THE LATEST REVISION LEVEL. MODELS: 2000 (AN) Dakota **2001** 2000 (DN) Durango **2001** 1999 (WJ) Grand Cherokee **2001 ** NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 4.7L ENGINE AND A 45RFE **OR 545RFE** TRANSMISSION. SYMPTOM/CONDITION: Some vehicles **may exhibit one or more of the following performance conditions **: 1. A harsh 2-3 upshift causing a powertrain clunk or shudder when accelerating. 2. **A harsh 4-5 upshift ('01 Grand Cherokee only).** 3. **A harsh 5-4 downshift ('01 Grand Cherokee only).** NOTE: THIS REVISION TO THE TCM SOFTWARE ADDRESSES THE ABOVE SHIFT QUALITY CONDITIONS FOR ALL VEHICLES AND, ADDS A FINAL GEAR RATIO TO THE **1999 AND 2000 MY** GRAND CHEROKEE TRANSMISSION ONLY. (2001 MY GRAND CHEROKEE ALREADY HAS THIS UPGRADE.) NOTE: TO MAINTAIN EMISSIONS COMPLIANCE, GRAND CHEROKEE VEHICLES THAT ARE EQUIPPED WITH A FEDERAL EMISSION SYSTEM (SALES CODE NAA) MUST HAVE THEIR PCM REPROGRAMMED. IF THE SOFTWARE LEVEL IS AT OR HIGHER THAN THOSE IN THE OVERVIEW ABOVE, OR IF THE GRAND CHEROKEE HAS A CALIFORNIA EMISSIONS SYSTEM (SALES CODE NAE), REPROGRAMMING IS NOT NECESSARY. DIAGNOSIS PROCEDURES: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRBIII(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 performing this repair. If no DTC's are present, and the above symptom has been experienced, perform the Repair Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts > Page 2405 Procedure. NOTE: **IF OTHER PERFORMANCE ISSUES REMAIN AFTER THE REPAIR PROCEDURE HAS BEEN PERFORMED THEY DO NOT RELATE TO THIS BULLETIN. REFER TO THE PROPER SERVICE OR DIAGNOSTIC PROCEDURES MANUAL(S) FOR FURTHER ASSISTANCE.** PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD **2093 OR HIGHER AND DRB III(R) VERSION 52.3 WILL BE IN THE DEALERSHIPS ON OCTOBER 15, 2001.)** REPAIR PROCEDURE: 1. Log onto the MDS2 (Mopar Diagnostic System). 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III(R), MDS2, AND VEHICLE ESTABLISH COMMUNICATION. 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. 3. Push the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) 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. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. 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, 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 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts > Page 2406 7. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 8. 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Powertrain Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2412 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2413 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2414 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts Powertrain Control Module: All Technical Service Bulletins A/T - 45RFE/545RFE Harsh Upshifts/Downshifts NUMBER: 18-025-01 GROUP: Vehicle Performance DATE: October 15, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-09-00, DATED SEPTEMBER 15, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. **ASTERISKS** HAVE BEEN USED TO HIGHLIGHT CHANGES. THIS BULLETIN ADDS A MODEL YEAR AND REQUIRES A REPROGRAMMING OF THE 1999 AND 2000 GRAND CHEROKEE POWERTRAIN CONTROL MODULE (PCM). SUBJECT: 45RFE **and 545RFE Shift** Quality Enhancements for the** 2-3, 4-5, and 5-4** Shifts OVERVIEW: This bulletin involves selectively erasing and reprogramming the **Transmission Control Module (TCM) with new software: '99-'01 WJ (PN 05019701AC Ver 9.3), '00 AN/DN (PN 05018454AB Ver 9.1), or '01 AN/DN (PN 56028285A1 Ver 8.4), and requires reprogramming of the Powertrain Control Module (PCM) for the 1999 and 2000 Grand Cherokees only (with calibration 99Cal20 (1999) or 00Cal17 (2000).** NOTE: THE 2001 GRAND CHEROKEE DOES NOT REQUIRE REPROGRAMMING OF THE PCM AS IT IS ALREADY AT THE CORRECT CALIBRATION LEVEL. NOTE: WHENEVER A PCM OR TCM IS REPLACED OR REPROGRAMMED, THE SOFTWARE OF THE PCM MUST BE VERIFIED AS HAVING THE LATEST REVISION LEVEL. MODELS: 2000 (AN) Dakota **2001** 2000 (DN) Durango **2001** 1999 (WJ) Grand Cherokee **2001 ** NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 4.7L ENGINE AND A 45RFE **OR 545RFE** TRANSMISSION. SYMPTOM/CONDITION: Some vehicles **may exhibit one or more of the following performance conditions **: 1. A harsh 2-3 upshift causing a powertrain clunk or shudder when accelerating. 2. **A harsh 4-5 upshift ('01 Grand Cherokee only).** 3. **A harsh 5-4 downshift ('01 Grand Cherokee only).** NOTE: THIS REVISION TO THE TCM SOFTWARE ADDRESSES THE ABOVE SHIFT QUALITY CONDITIONS FOR ALL VEHICLES AND, ADDS A FINAL GEAR RATIO TO THE **1999 AND 2000 MY** GRAND CHEROKEE TRANSMISSION ONLY. (2001 MY GRAND CHEROKEE ALREADY HAS THIS UPGRADE.) NOTE: TO MAINTAIN EMISSIONS COMPLIANCE, GRAND CHEROKEE VEHICLES THAT ARE EQUIPPED WITH A FEDERAL EMISSION SYSTEM (SALES CODE NAA) MUST HAVE THEIR PCM REPROGRAMMED. IF THE SOFTWARE LEVEL IS AT OR HIGHER THAN THOSE IN THE OVERVIEW ABOVE, OR IF THE GRAND CHEROKEE HAS A CALIFORNIA EMISSIONS SYSTEM (SALES CODE NAE), REPROGRAMMING IS NOT NECESSARY. DIAGNOSIS PROCEDURES: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRBIII(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 performing this repair. If no DTC's are present, and the above symptom has been experienced, perform the Repair Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts > Page 2419 Procedure. NOTE: **IF OTHER PERFORMANCE ISSUES REMAIN AFTER THE REPAIR PROCEDURE HAS BEEN PERFORMED THEY DO NOT RELATE TO THIS BULLETIN. REFER TO THE PROPER SERVICE OR DIAGNOSTIC PROCEDURES MANUAL(S) FOR FURTHER ASSISTANCE.** PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD **2093 OR HIGHER AND DRB III(R) VERSION 52.3 WILL BE IN THE DEALERSHIPS ON OCTOBER 15, 2001.)** REPAIR PROCEDURE: 1. Log onto the MDS2 (Mopar Diagnostic System). 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III(R), MDS2, AND VEHICLE ESTABLISH COMMUNICATION. 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. 3. Push the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) 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. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. 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, 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 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts > Page 2420 7. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 8. 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Powertrain Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2426 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2427 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2428 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2429 Powertrain Control Module: Specifications Powertrain Control Module Mounting Screws ................................................................................................................................. 3-5 Nm (30-40 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2430 Powertrain Control Module: Locations Powertrain Control Module Fig. 9 PCM Location The Powertrain Control Module (PCM) is located in the engine compartment. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2433 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2434 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2435 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2436 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2437 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2438 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2439 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2440 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2441 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2442 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2443 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2444 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2445 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2446 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2447 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2448 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2449 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2450 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2451 Powertrain Control Module: Connector Views Powertrain Control Module C1 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2452 Powertrain Control Module C2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2453 Powertrain Control Module C3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2454 Powertrain Control Module: Electrical Diagrams System Diagrams Refer to Powertrain Management/Diagrams/Electrical for wiring diagrams. See: Diagrams/Electrical Diagrams PCM Communication System Schematic Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2455 2001 Dodge JTEC System Federal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2456 2001 Dodge JTEC System California Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2457 Powertrain Control Module: Description and Operation Fig. 9 PCM Location POWERTRAIN CONTROL MODULE The Powertrain Control Module (PCM) is located in the engine compartment. The PCM is referred to as JTEC. The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. NOTE: PCM Inputs: A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - Auto shutdown (ASD) sense - Battery temperature - Battery voltage - Brake switch - CCD bus (+) circuits - CCD bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for DRB scan tool - Engine coolant temperature sensor - Fuel level - Generator (battery voltage) output - Ignition circuit sense (ignition switch in ON/OFF/crank/run position) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2458 - Intake manifold air temperature sensor - Leak detection pump (switch) sense (if equipped) - Manifold Absolute Pressure (MAP) sensor - Oil pressure - Output shaft speed sensor - Overdrive/override switch - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transmission governor pressure sensor - Transmission temperature sensor - Vehicle speed inputs from ABS or RWAL system NOTE: PCM Outputs: A/C clutch relay - Auto shutdown (ASD) relay - CCD bus (+A) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Generator lamp (if equipped) - Idle Air Control (IAC) motor Ignition coil - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through CCD circuits. - Overdrive indicator lamp (if equipped) - Radiator cooling fan - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through CCD circuits. - Transmission convertor clutch circuit - Transmission 3-4 shift solenoid - Transmission relay - Transmission temperature lamp (if equipped) - Transmission variable force solenoid MODES OF OPERATION As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. For example, the PCM must calculate different injector pulse width and ignition timing for idle than it does for wide open throttle (WOT). The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (O2S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (O2S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to-1 part fuel. By monitoring the exhaust oxygen content through the O2S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise - Acceleration Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2459 - Deceleration - Wide open throttle (WOT) - Ignition switch OFF The ignition switch ON, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. Ignition Switch (KEY-ON) Mode This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: The PCM pre-positions the idle air control (IAC) motor. - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the engine is operating or the starter motor is engaged. - The 02S sensor heater element is energized via the ASD relay. The 02S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. Engine Start-Up Mode This is an Open Loop mode. The following actions occur when the starter motor is engaged.The PCM receives inputs from: Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Starter motor relay - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector ON and OFF. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. Engine Warm-Up Mode This is an Open Loop mode. During engine warmup, the PCM receives inputs from: Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) - Park/neutral switch (gear indicator signal-auto.trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector ON and OFF. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the clutch relay. This is done if A/C has been selected by the vehicle operator and requested by the A/C thermostat. - When engine has reached operating temperature, the PCM will begin monitoring 02S sensor input. The system will then leave the warm-up mode and go into closed loop operation. Idle Mode When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: Air conditioning select signal (if equipped) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2460 - Air conditioning request signal (if equipped) - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector ON and OFF. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio by varying injector pulse width.It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. Cruise Mode When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen (O2S) sensors Based on these inputs, the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector ON and OFF. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control ('AC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil ON and OFF. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. Acceleration Mode This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. Deceleration Mode When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed sensor If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2461 The PCM adjusts ignition timing by turning the ground path to the coil ON and OFF. Wide Open Throttle Mode This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) During wide open throttle conditions, the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector ON and OFF. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil ON and OFF. ignition switch OFF Mode When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. 5 VOLT SUPPLIES Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. Primary 5-volt supply: supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5-volt supply: supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (if equipped with an RE automatic transmission). IGNITION CIRCUIT SENSE This circuit ties the ignition switch to the Power- train Control Module (PCM). The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Voltage ON the ignition input can be as low as 6 volts and the PCM will still function. Voltage is supplied to this circuit to power the PCM's 8-volt regulator and to allow the PCM to perform fuel, ignition and emissions control functions. POWER GROUND The Powertrain Control Module (PCM) has 2 main grounds. Both of these grounds are referred to as power grounds. All of the high-current, noisy, electrical devices are connected to these grounds as well as all of the sensor returns. The sensor return comes into the sensor return circuit, passes through noise suppression, and is then connected to the power ground. The power ground is used to control ground circuits for the following PCM loads: Generator field winding - Fuel injectors - Ignition coil(s) - Certain relays/solenoids - Certain sensors SENSOR RETURN The Sensor Return circuits are internal to the Powertrain Control Module (PCM). Sensor Return provides a low-noise ground reference for all engine control system sensors. Refer to Power Grounds for more information. SIGNAL GROUND Signal ground provides a low noise ground to the data link connector. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2462 Powertrain Control Module: Service and Repair REMOVAL USE THE DRB SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. Fig. 10 PCM Location And Mounting The PCM is located in the engine compartment. To avoid possible voltage spike damage to the PCM, ignition key must be OFF and negative battery cable must be disconnected before unplugging PCM connectors. 1. Disconnect negative battery cable at battery. 2. Remove cover over electrical connectors. Cover snaps onto PCM. 3. Carefully unplug the three 32-way connectors from PCM. 4. Remove three PCM mounting bolts and remove PCM from vehicle. INSTALLATION USE THE DRB SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. 1. Install PCM and mounting bolts to vehicle. 2. Tighten bolts to 3-5 Nm (30-40 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 cover over electrical connectors. Cover snaps onto PCM. 6. Install battery cable. 7. Use the DRB scan tool to reprogram new PCM with vehicles original Identification Number (VIN) and original vehicle mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations Fig. 7 Fuel Gauge Sending Unit Location - Typical Module The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module. The fuel pump module is located inside of fuel tank. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2466 Fuel Level Sensor: Description and Operation FUEL LEVEL SENDING UNIT / SENSOR The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation: A constant input voltage source of about 12 volts (battery voltage) is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2467 Fuel Level Sensor: Service and Repair REMOVAL Fig. 7 Fuel Gauge Sending Unit Location - Typical Module The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module. The fuel pump module is located inside of fuel tank. 1. Remove fuel tank. 2. Remove fuel pump module. 3. Unplug 4-way electrical connector. 4. Disconnect 2 sending unit wires at 4-way connector. The locking collar of connector must be removed before wires can be released from connector. Note location of wires within 4-way connector. Fig. 8 Fuel Gauge Sending Unit Lock Tab/Tracks Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2468 5. The sending unit is retained to pump module with a small lock tab and notch. Carefully push lock tab to the side and away from notch while sliding sending unit downward on tracks for removal. Note wire routing while removing unit from module. INSTALLATION The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module. The fuel pump module is located inside of fuel tank. 1. Position sending unit into tracks. Note wire routing. 2. Push unit on tracks until lock tab snaps into notch. 3. Connect 2 sending unit wires into 4-way connector and install locking collar. 4. Connect 4-way electrical connector to module. 5. Install fuel pump module. 6. Install fuel tank. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications Idle Air Control (IAC) Motor: Specifications IAC Motor-To-Throttle Body Bolts .......................................................................................................................................................... 7 Nm (60 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 2472 Idle Air Control (IAC) Motor: Locations The IAC motor is located on the throttle body. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 2473 Idle Air Control Motor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 2474 Idle Air Control (IAC) Motor: Description and Operation The IAC stepper motor is mounted to the throttle body, and regulates the amount of air bypassing the control of the throttle plate. As engine loads and ambient temperatures change, engine rpm changes. A pintle on the IAC stepper motor protrudes into a passage in the throttle body, controlling air flow through the passage. The IAC is controlled by the Powertrain Control Module (PCM) to maintain the target engine idle speed. At idle, engine speed can be increased by retracting the IAC motor pintle and allowing more air to pass through the port, or it can be decreased by restricting the passage with the pintle and diminishing the amount of air bypassing the throttle plate. The IAC is called a stepper motor because it is moved (rotated) in steps, or increments. Opening the IAC opens an air passage around the throttle blade which increases RPM. The PCM uses the IAC motor to control idle speed (along with timing) and to reach a desired MAP during decel (keep engine from stalling). The IAC motor has 4 wires with 4 circuits. Two of the wires are for 12 volts and ground to supply electrical current to the motor windings to operate the stepper motor in one direction. The other 2 wires are also for 12 volts and ground to supply electrical current to operate the stepper motor in the opposite direction. To make the IAC go in the opposite direction, the PCM just reverses polarity on both windings. If only 1 wire is open, the IAC can only be moved 1 step (increment) in either direction. To keep the IAC motor in position when no movement is needed, the PCM will energize both windings at the same time. This locks the IAC motor in place. In the IAC motor system, the PCM will count every step that the motor is moved. This allows the PCM to determine the motor pintle position. If the memory is cleared, the PCM no longer knows the position of the pintle. So at the first key ON, the PCM drives the IAC motor closed, regardless of where it was before. This zeros the counter, From this point the PCM will back out the IAC motor and keep track of its position again. When engine rpm is above idle speed, the IAC is used for the following: - OFF-idle dashpot (throttle blade will close quickly but idle speed will not stop quickly) - Deceleration air flow control - A/C compressor load control (also opens the passage slightly before the compressor is engaged so that the engine rpm does not dip down when the compressor engages) - Power steering load control The PCM can control polarity of the circuit to control direction of the stepper motor. IAC Stepper Motor Program: The PCM is also equipped with a memory program that records the number of steps the IAC stepper motor most recently advanced to during a certain set of parameters. For example: The PCM was attempting to maintain a 1000 rpm target during a cold start-up cycle. The last recorded number of steps for that may have been 125. That value would be recorded in the memory cell so that the next time the PCM recognizes the identical conditions, the PCM recalls that 125 steps were required to maintain the target. This program allows for greater customer satisfaction due to greater control of engine idle. Another function of the memory program, which occurs when the power steering switch (if equipped), or the A/C request circuit, requires that the IAC stepper motor control engine rpm, is the recording of the last targeted steps into the memory cell. The PCM can anticipate A/C compressor loads. This is accomplished by delaying compressor operation for approximately 0.5 seconds until the PCM moves the IAC stepper motor to the recorded steps that were loaded into the memory cell. Using this program helps eliminate idle-quality changes as loads change. Finally, the PCM incorporates a "No-Load" engine speed limiter of approximately 1800 - 2000 rpm, when it recognizes that the TPS is indicating an idle signal and IAC motor cannot maintain engine idle. 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 IAC motor through the PCM. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 2475 Idle Air Control (IAC) Motor: Service and Repair REMOVAL Fig. 35 Throttle Body, Sensor And Electrical Connectors The IAC motor is located on the throttle body. 1. Remove air duct and air resonator box at throttle body. 2. Disconnect electrical connector from IAC motor. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 2476 Fig. 22 Mounting Bolts (Screws) - IAC Motor 3. Remove two mounting bolts (screws). 4. Remove IAC motor from throttle body. INSTALLATION 1. Install IAC motor to throttle body. 2. Install and tighten two mounting bolts (screws) to 7 Nm (60 in. lbs.) torque. 3. Install electrical connector. 4. Install air duct/air box to throttle body. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2481 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2482 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2483 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2484 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2485 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2486 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2487 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2488 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2489 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2490 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2491 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2492 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2493 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2494 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2495 Information Bus: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2496 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2497 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2498 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2499 Information Bus: Connector Views Diagnostic Junction Port Diagnostic Junction Port Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2500 Information Bus: Electrical Diagrams Communication Wiring Diagrams Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2501 8w-18-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2502 8w-18-3 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 2503 Information Bus: Description and Operation PROGRAMMABLE COMMUNICATION INTERFACE (PCI) The Programmable Communication Interface (PCI) data bus system is a single wire multiplexed network used for vehicle communications. Multiplexing is a system that enables the transmission of binary encoded messages over a single channel or circuit between multiple modules. All DaimlerChrysler vehicles use this principle for communication between various microprocessor-based electronic control modules. The PCI bus circuit is identified as D25 and is yellow with a violet tracer, or violet with a yellow tracer, depending upon the application. Additional tracer colors may be added to the violet in order to distinguish between different module connections. The modules are wired in parallel. Connections are made in the harness using splices. Diagnostic Junction Port One splice, called the Diagnostic Junction Port, serves as the "Hub" of the bus. The Diagnostic Junction Port provides an access point to isolate most of the modules on the bus in order to assist in diagnosing the circuit. The following modules are used on the DN: Airbag Control Module - A/C Heater Control - Central Timer Module - Controller Antilock Brake - Compass Mini-Trip Computer - Electro/Mechanical Instrument Cluster - Powertrain Control Module - Radio - Sentry Key Immobilizer Module - Transfer Case Control Module - Transmission Control Module The PCI data bus exceeds the Society of Automotive Engineers (SAE) J1850 Standard for Class B Multiplexing. Many of the electronic control modules in a vehicle require information from the same sensing device. In the past, if information from one sensing device was required by several controllers, a wire from each controller needed to be connected in parallel to that sensor. In addition, each controller utilizing analog sensors required an Analog/Digital (A/D) converter in order to "read" these sensor inputs. Multiplexing reduces wire harness complexity, sensor current loads and controller hardware because each sensing device is connected to only one controller, which reads and distributes the sensor information to the other controllers over the data bus. Also, because each controller on the data bus can access the controller sensor inputs to every other controller on the data bus, more function and feature capabilities are possible. In addition to reducing wire harness complexity, component sensor current loads and controller hardware, multiplexing offers a diagnostic advantage. A multiplex system allows the information flowing between controllers to be monitored using a diagnostic scan tool. The DaimlerChrysler system allows an electronic control module to broadcast message data out onto the bus where all other electronic control modules can "hear" the messages that are being sent. When a module hears a message on the data bus that it requires, it relays that message to its micro-processor. Each module ignores the messages on the data bus that are being sent to other electronic control modules. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 2504 The PCI data bus messages are carried over the bus in the form of Variable Pulse Width Modulated (VPWM) signals. The PCI data bus speed is an average 10.8 Kilo-bits per second (Kbps). By comparison, the prior two-wire Chrysler Collision Detection (CCD) data bus system is designed to run at 7.8125 Kbps. Since there is only voltage present when the modules transmit and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use DRB III lab scope. The 12 V square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between zero and about 7-1/2 volts. Refer to the figure for some typical displays. The voltage network used to transmit messages requires biasing and termination. Each module on the PCI data bus system provides its own biasing and termination in order to transmit and receive messages. Each module (also referred to as a node) terminates the bus through a terminating resistor and a terminating capacitor. There are two types of nodes on the bus. The dominant node terminates the bus through a 1 KW resistor and a 3300 pF capacitor. The Powertrain Control Module (PCM) is the only dominant node for the PCI data bus system. A standard node terminates the bus through an 11 KW resistor and a 330 pF capacitor. The modules bias the bus when transmitting a message. The PCI bus uses low and high voltage levels to generate signals. Low voltage is around 0 volts and the high voltage is about 7-1/2 volts. The low and high voltage levels are generated by means of variable-pulse width modulation to form signals of varying length. The Variable Pulse Width Modulation (VPWM) used in PCI bus messaging is a method in which both the state of the bus and the width of the pulse are used to encode bit information. A "zero" bit is defined as a short low pulse or a long high pulse. A "one" bit is defined as a long low pulse or a short high pulse. A low (passive) state on the bus does not necessarily mean a zero bit. It also depends upon pulse width. If the width is short, it stands for a zero bit. If the width is long, it stands for a one bit. Similarly, a high (active) state does not necessarily mean a one bit. This too depends upon pulse width. If the width is short, it stands for a one bit. If the width is long, it stands for a zero bit. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 2505 In the case where there are successive zero or one data bits, both the state of the bus and the width of the pulse are changed alternately. This encoding scheme is used for two reasons. First, this ensures that only one symbol per transition and one transition per symbol exists. On each transition, every transmitting module must decode the symbol on the bus and begin timing of the next symbol. Since timing of the next symbol begins with the last transition detected on the bus, all of the modules are re-synchronized with each symbol. This ensures that there are no accumulated timing errors during PCI data bus communication. The second reason for this encoding scheme is to guarantee that the zero bit is the dominant bit on the bus. When two modules are transmitting simultaneously on the bus, there must be some form of arbitration to determine which module will gain control. A data collision occurs when two modules are transmitting different messages at the same time. When a module is transmitting on the bus, it is reading the bus at the same time to ensure message integrity. When a collision is detected, the module that transmitted the one bit stops sending messages over the bus until the bus becomes idle. Each module is capable of transmitting and receiving data simultaneously. The typical PCI bus message has the following four components: - Message Header - One to three bytes in length. The header contains information identifying the message type and length, message priority, target module(s) and sending module. - Data Byte(s) - This is the actual message that is being sent. - Cyclic Redundancy Check (CRC) Byte - This byte is used to detect errors during a message transmission. - In-Frame Response (IFR) byte(s) - If a response is required from the target module(s), it can be sent during this frame. This function is described in greater detail in the following paragraph. The IFR consists of one or more bytes, which are transmitted during a message. If the sending module requires information to be received immediately, the target module(s) can send data over the bus during the original message. This allows the sending module to receive time-critical information without having to wait for the target module to access the bus. After the IFR is received, the sending module broadcasts an End Of Frame (EOF) message and releases control of the bus. The PCI data bus can be monitored using the DRB III scan tool. It is possible, however, for the bus to pass all DRB III tests and still be faulty if the voltage parameters are all within the specified range and false messages are being sent. PCI Bus Failure Modes The PCI Bus failure modes are broken down into two categories. Complete PCI Bus Communication Failure and individual module no response. Causes of complete PCI Bus Communication Failure include a short to ground or battery on the PCI circuit. Individual module no response can be caused by an open circuit at either the Diagnostic Junction Port or the module, or an open battery or ground circuit to the affected module. Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: All gauges on the EMIC stay at zero - All telltales on EMIC illuminate - EMIC backlighting at full intensity - Dashed lines in the Compass Mini-Trip Computer display - No response received from any module on the PCI bus (except the PCM) - No start (if equipped with Sentry Key immobilizer) Symptoms of Individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRB III. Diagnosis starts with symptom identification. If a complete PCI Bus Communication Failure is suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRB III. If any modules are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI circuit or power supply and ground circuits. The DRB III may display "BUS +A SIGNAL OPEN" or "NO RESPONSE" to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRB III and in no way indicates whether or not the PCI bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Auto Shut Down (ASD) Relay: Locations Power Distribution Center Automatic Shut Down Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2509 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2510 Auto Shut Down (ASD) Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2511 Automatic Shut Down Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2512 Auto Shut Down (ASD) Relay: Description and Operation AUTO SHUT DOWN RELAY PCM Output The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit ON and OFF. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. ASD Sense - PCM Input A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2513 Auto Shut Down (ASD) Relay: Testing and Inspection Fig. 1 ASD And Fuel Pump Relay Terminals - Type 1 Fig. 2 ASD And Fuel Pump Terminals - Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2514 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2515 Auto Shut Down (ASD) Relay: Service and Repair Fig. 3 Power Distribution Center (PDC) Location REMOVAL The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Locations Malfunction Indicator Lamp: Locations The MIL is located in the Information Center area of the instrument cluster overlay, to the left of center. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Locations > Page 2519 Malfunction Indicator Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Check Engine ...................................................................................................................................... ............................................................... PC194 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Locations > Page 2520 Malfunction Indicator Lamp: Description and Operation A Malfunction Indicator Lamp (MIL) is standard equipment on all instrument clusters. The MIL is located in the Information Center area of the instrument cluster overlay, to the left of center. The MIL consists of a stencilled cutout of the International Control and Display Symbol icon for "Engine" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber lens behind the cutout in the opaque layer of the overlay causes the icon to appear in amber through the translucent outer layer of the overlay when the indicator is illuminated from behind by a Light Emitting Diode (LED) soldered onto the instrument cluster electronic circuit board. The MIL is serviced as a unit with the instrument cluster. The Malfunction Indicator Lamp (MIL) gives an indication to the vehicle operator when the Powertrain Control Module (PCM) has recorded a Diagnostic Trouble Code (DTC) for an On-Board Diagnostics II (OBDII) emissions-related circuit or component malfunction. The MIL is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the PCM over the Programmable Communications Interface (PCI) data bus. The MIL Light Emitting Diode (LED) receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions; therefore, the LED will always be OFF when the ignition switch is in any position except ON or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the MIL for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the indicator is illuminated for about seven seconds as a bulb test. - PCM Lamp-ON Message - Each time the cluster receives a lamp-on message from the PCM, the indicator will be illuminated. The indicator can be flashed ON and OFF, or illuminated solid, as dictated by the PCM message. For some DTC's, if a problem does not recur, the PCM will send a lamp-off message automatically. Other DTC's may require that a fault be repaired and the PCM be reset before a lamp-OFF message will be sent. For more information on the PCM, and the DTC set and reset parameters, (Refer to EMISSIONS CONTROL - OPERATION). - Communication Error - If the cluster receives no lamp-on message from the PCM for twenty seconds, the MIL is illuminated by the instrument cluster to indicate a loss of bus communication. The indicator remains controlled and illuminated by the cluster until a valid lamp-ON message is received from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the indicator will be turned ON during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the fuel and emissions system circuits and sensors to decide whether the system is in good operating condition. The PCM then sends the proper lamp-ON or lamp-OFF messages to the instrument cluster. If the instrument cluster turns ON the MIL after the bulb test, it may indicate that a malfunction has occurred and that the fuel and emissions systems may require service. For proper diagnosis of the fuel and emissions systems, the PCM, the PCI data bus, or the message inputs to the instrument cluster that control the MIL, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications Manifold Absolute Pressure (MAP) Sensor: Specifications MAP Sensor Mounting Screws ............................................................................................................ ..................................................... 3 Nm (25 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2524 Manifold Absolute Pressure (MAP) Sensor: Locations Fig. 27 MAP And ECT Sensor Locations The MAP sensor is located on the front of the intake manifold. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2525 Manifold Absolute Pressure Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2526 Manifold Absolute Pressure (MAP) Sensor: Description and Operation The MAP sensor is located on the front of the intake manifold. An O-ring seals the sensor to the intake manifold. The MAP sensor is used as an input to the Powertrain Control Module (PCM). It contains a silicon based sensing unit to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When manifold absolute pressure (MAP) equals Barometric pressure, the pulse width will be at maximum. A 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5V and full scale is 4.5V. For a pressure swing of 0-15 psi, the voltage changes 4.0V To operate the sensor, it is supplied a regulated 4.8 to 5.1 volts. Ground is provided through the low-noise, sensor return circuit at the PCM. The MAP sensor input is the number one contributor to fuel injector pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or at a higher altitude, because the air density changes with altitude. It will also help to correct for varying barometric pressure. Barometric pressure and altitude have a direct inverse correlation; as altitude goes up, barometric goes down. At key-ON, the PCM powers up and looks at MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure (relative to altitude). Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key-on. The difference between current voltage and what it was at key-on, is manifold vacuum. During key-ON (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring a known good sensor. As the altitude increases, the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key-ON, the barometric pressure needs to be updated. Any time the PCM sees Wide Open Throttle (WOT), based upon Throttle Position Sensor (TPS) angle and RPM, it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor input to aid in calculating the following: - Manifold pressure - Barometric pressure - Engine load - Injector pulse-width - Spark-advance programs - Shift-point strategies (certain automatic transmissions only) - Idle speed - Decel fuel shutoff The MAP sensor signal is provided from a single piezoresistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As manifold pressure changes, the diaphragm moves causing the element to deflect, which stresses the silicone. When silicone is exposed to stress, its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally. The sensor also contains electronics that condition the signal and provide temperature compensation. The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; meaning as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg. Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is approximately 29.92 in Hg. For every 100 feet of altitude, barometric pressure drops 0.10 in. Hg. If a storm goes through it can change barometric pressure from what should be present for that altitude. You should know what the average pressure and corresponding barometric pressure is for your area. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2527 Manifold Absolute Pressure (MAP) Sensor: Service and Repair Fig. 27 MAP And ECT Sensor Locations REMOVAL The MAP sensor is located on the front of the intake manifold. An O-ring seals the sensor to the intake manifold. 1. Disconnect electrical connector at sensor. 2. Clean area around MAP sensor. 3. Remove 2 sensor mounting bolts. 4. Remove MAP sensor from intake manifold. INSTALLATION The MAP sensor is located on the front of the intake manifold. An O-ring seals the sensor to the intake manifold. 1. Clean MAP sensor mounting hole at intake manifold. 2. Check MAP sensor O-ring seal for cuts or tears. 3. Position sensor into manifold. 4. Install MAP sensor mounting bolts (screws). Tighten screws to 3 Nm (25 In. lbs.) torque. 5. Connect electrical connector. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams Engine Oil Pressure Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 2531 Oil Pressure Sensor: Description and Operation DESCRIPTION The 2-wire, electrical/mechanical engine oil pressure sensor (sending unit) is located in an engine oil pressure gallery. OPERATION The oil pressure sensor uses two circuits. They are: ^ A signal to the PCM relating to engine oil pressure ^ A sensor ground through the PCM's sensor return The oil pressure sensor returns a voltage signal back to the PCM relating to engine oil pressure. This signal is then transferred (bussed) to the instrument panel on a CCD bus circuit to operate the oil pressure gauge and the check gauges lamp. Ground for the sensor is provided by the PCM through a low noise sensor return. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 2532 Oil Pressure Sensor: Service and Repair REMOVAL 1. Disconnect the negative cable from the battery. 2. Raise vehicle on hoist. 3. Remove front splash shield. 4. Disconnect oil pressure sender wire (Fig. 107). 5. Remove the pressure sender (Fig. 107). INSTALLATION 1. Install oil pressure sender. 2. Connect oil pressure sender wire. 3. Install front splash shield. 4. Lower vehicle. 5. Connect the negative battery cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Oxygen Sensor .................................................................................................................................... .................................................... 30 Nm (22 Ft. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System Oxygen Sensor: Locations Engine Compartment/Exhaust System The upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. The right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System > Page 2538 Oxygen Sensor: Locations OBD-II Heated Oxygen Sensor Numbering Convention - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2539 Oxygen Sensor: Diagrams Oxygen Sensor 1/1 Upstream (California) Oxygen Sensor 1/2 Downstream (California) Oxygen Sensor 1/2 Downstream (Except California) Oxygen Sensor 2/1 Upstream (California) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2540 Oxygen Sensor 2/2 Downstream (California) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2541 Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2542 Oxygen Sensor Downstream Heater Relay (California) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2543 Oxygen Sensor: Service Precautions WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Application O(2) Sensor Configuration Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Application > Page 2546 Oxygen Sensor: Application and ID OBD-II Heated Oxygen Sensor Numbering Convention - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 2547 Oxygen Sensor: Description and Operation The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Depending on the emission package, the vehicle may use a total of either 2 or 4 sensors. NAA Emissions Package: Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2). With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. NAS or NAE Emissions Package: On this emissions package, 4 sensors are used: 2 upstream (referred to as 1/1 and 2/1) and 2 downstream (referred to as 1/2 and 2/2). With this emission package, the right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. An O2 sensor is a galvanic battery that provides the PCM with a voltage signal (0-1 volt) inversely proportional to the amount of oxygen in the exhaust. In other words, if the oxygen content is low, the voltage output is high; if the oxygen content is high the output voltage is low. The PCM uses this information to adjust injector pulse-width to achieve the 14.7-to-1 air/fuel ratio necessary for proper engine operation and to control emissions. The O2 sensor must have a source of oxygen from outside of the exhaust stream for comparison. Current O2 sensors receive their fresh oxygen (outside air) supply through the wire harness. This is why it is important to never solder an O2 sensor connector, or pack the connector with grease. Four wires (circuits) are used on each O2 sensor: a 12-volt feed circuit for the sensor heating element; a ground circuit for the heater element; a low-noise sensor return circuit to the PCM, and an input circuit from the sensor back to the PCM to detect sensor operation. Oxygen Sensor Heater Relay: If the vehicle is equipped with 4 oxygen sensors, a separate oxygen sensor relay is used to supply voltage to the sensor heating elements. This particular relay is used only for the 1/2 and 2/2 downstream sensors. Voltage for the other 2 sensor heating elements is supplied directly from the ASD relay. To avoid the large simultaneous current surge needed to operate all 4 sensors, power is delayed to the 2 downstream heater elements by the PCM for approximately 2 seconds. Oxygen Sensor Heater Elements: The O2 sensor uses a Positive Thermal Co-efficient (PTC) heater element. As temperature increases, resistance increases. At ambient temperatures around 70 °F, the resistance of the heating element is approximately 13.5 ohms on the this engine. As the sensor's temperature increases, resistance in the heater element increases. This allows the heater to maintain the optimum operating temperature of approximately 930 ° - 1100 °F (500 ° - 600 °C). Although the sensors operate the same, there are physical differences, due to the environment that they operate in, that keep them from being interchangeable. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation, the PCM monitors certain O2 sensor input(s) along with other inputs, and adjusts the injector pulse width accordingly. During Open Loop operation, the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. Upstream Sensor - Engine Equipped With 2 Sensors: The upstream sensor (1/1) provides an input voltage to the PCM. The input tells the PCM the oxygen content of the exhaust gas. The PCM uses this information to fine tune fuel delivery to maintain the correct oxygen content at the downstream oxygen sensor. The PCM will change the air/fuel ratio until the upstream sensor inputs a voltage that the PCM has determined will make the downstream sensor output (oxygen content) correct. The upstream oxygen sensor also provides an input to determine catalytic convertor efficiency. Downstream Sensor - Engine Equipped With 2 Sensors: The downstream oxygen sensor (1/2) is also used to determine the correct air-fuel ratio. As the oxygen content changes at the downstream sensor, the PCM calculates how much air-fuel ratio change is required. The PCM then looks at the upstream oxygen sensor voltage and changes fuel delivery until the upstream sensor voltage changes enough to correct the downstream sensor voltage (oxygen content). The downstream oxygen sensor also provides an input to determine catalytic convertor efficiency. Upstream Sensors - Engine Equipped With 4 Sensors: Two upstream sensors are used (1/1 and 2/1). The 1/1 sensor is the first sensor to receive exhaust gases from the # 1 cylinder. They provide an input voltage to the PCM. The input tells the PCM the oxygen content of the exhaust gas. The PCM uses this information to fine tune fuel delivery to maintain the correct oxygen content at the downstream oxygen sensors. The PCM will change the air/fuel ratio until the upstream sensors input a voltage that the PCM has determined will make the downstream sensors output (oxygen content) correct. The upstream oxygen sensors also provide an input to determine mini-catalyst efficiency. Main catalytic convertor efficiency is not calculated with this package. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 2548 Downstream Sensors - Engine Equipped With 4 Sensors: Two downstream sensors are used (1/2 and 2/2). The downstream sensors are used to determine the correct air-fuel ratio. As the oxygen content changes at the downstream sensor, the PCM calculates how much air-fuel ratio change is required. The PCM then looks at the upstream oxygen sensor voltage, and changes fuel delivery until the upstream sensor voltage changes enough to correct the downstream sensor voltage (oxygen content). The downstream oxygen sensors also provide an input to determine mini-catalyst efficiency. Main catalytic convertor efficiency is not calculated with this package. Engines equipped with either a downstream sensor(s), or a post-catalytic sensor, will monitor catalytic convertor efficiency. If efficiency is below emission standards, the Malfunction Indicator Lamp (MIL) will be illuminated and a Diagnostic Trouble Code (DTC) will be set. Refer to Monitored Systems in Emission Control Systems for additional information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 2549 Oxygen Sensor: Service and Repair REMOVAL Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. For sensor operation, it must have a comparison source of oxygen from outside the exhaust system. This fresh air is supplied to the sensor through its pigtail wiring harness. Fig. 28 Upstream Oxygen Sensor Locations Fig. 29 Downstream Oxygen Sensor Location Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 2550 Fig. 30 Pre-Catalyst/Post-Catalyst Oxygen Sensor Locations Fig. 31 Left/Right Oxygen Sensor Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 2551 Fig. 32 Oxygen Sensor Locations 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 O2S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove the O2S sensor with an oxygen sensor removal and installation tool. 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 O2S sensor. Tighten to 30 Nm (22 ft. lbs.) torque. 2. Connect the O2S sensor wire connector. 3. Lower the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations Oxygen Sensor Relay: Locations Power Distribution Center Oxygen Sensor Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2555 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2556 Oxygen Sensor Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2557 Oxygen Sensor Downstream Heater Relay (California) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2558 Oxygen Sensor Relay: Description and Operation OXYGEN HEATER RELAY The oxygen (O2) sensor heater relay is located in the Powertrain Distribution Center (PDC). Refer to Oxygen Sensor for oxygen sensor relay information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2559 Oxygen Sensor Relay: Service and Repair Fig. 21 Power Distribution Center (PDC) REMOVAL The oxygen sensor heater relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The oxygen sensor heater relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications Power Steering Pressure Switch: Specifications Power Steering Pressure Switch ............................................................................................................................................... 14-22 Nm (124-195 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2563 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2564 Power Steering Pressure Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2565 Power Steering Pressure Switch: Description and Operation DESCRIPTION A pressure sensing switch is included in the power steering system (mounted on the high pressure line). This switch will be used only on vehicles equipped with a 4.7L V-8 engine and power steering. OPERATION The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high pump load and low engine rpm; such as during parking maneuvers. The PCM will then increase the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load. When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the normally closed switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling. When pump pressure drops to approximately 1379 kPa (200 psi), the switch circuit will re-close and engine idle speed will return to its previous setting. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2566 Power Steering Pressure Switch: Service and Repair REMOVAL The power steering pressure switch is installed in the power steering high-pressure hose. 1. Disconnect electrical connector from power steering pressure switch. 2. Place a small container or shop towel beneath switch to collect any excess fluid. 3. Remove switch. Use back-up wrench on power steering line to prevent line bending. INSTALLATION This switch is used only with 4.7L V-8 engine. 1. Install power steering switch into power steering line. 2. Tighten to 14-22 Nm (124-195 inch lbs.) torque. 3. Connect electrical connector to switch. 4. Check power steering fluid and add as necessary. 5. Start engine and again check power steering fluid. Add fluid if necessary. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions Central Timer Module: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2572 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2573 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2574 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2575 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2576 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2577 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2578 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2579 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2580 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2581 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2582 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2583 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2584 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2585 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2586 Central Timer Module: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2587 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2588 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2589 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2590 Central Timer Module: Electrical Diagrams 8w-45-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2591 8w-45-3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2592 8w-45-4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2593 8w-45-5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2594 8w-45-6 (Base) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2595 8w-45-7 (Light Package) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2596 8w-45-8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2597 8w-45-9 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2598 8w-45-10 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2599 8w-45-11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2600 8w-45-12 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2601 8w-45-13 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2602 8w-45-14 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2603 8w-45-15 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information Central Timer Module: Technician Safety Information WARNING: - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. 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. - NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information > Page 2606 Central Timer Module: Vehicle Damage Warnings Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. 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, Road Testing A Complaint Vehicle Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE REASSEMBLED. DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB III SCREEN WHILE IN MOTION. DO NOT HANG THE DRB III FROM THE REAR VIEW MIRROR OR OPERATE IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB III. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description Central Timer Module: Description and Operation Sytem Description The body system on the 2001 DN consists of a combination of modules that communicate over the PCI bus (Programmable Communication Interface multiplex system). Through the PCI bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all information to perform its function. It will only respond to messages "addressed" to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. All of the information about the functioning of all the systems is organized, controlled, and communicated by the PCI bus, which is described in the vehicle communication of this general information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 2609 Central Timer Module: Description and Operation Functional Operation Part 1 of 2 For additional information on the Base CTM refer to Instrument Panel, Gauges and Warning Indicators / Audible Warning Device. See: Instrument Panel, Gauges and Warning Indicators/Audible Warning Device AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. The Airbag Control Module (ACM) is an electronic module that monitors the airbag system for proper operation, stores diagnostic trouble code (DTCs), controls the airbag warning lamp and contains the sensor and actuator that is responsible for airbag deployment. There are no external impact sensors. The ACM is mounted on a special bracket that is fastened to the floor of the truck at the bottom of the instrument panel. It is located forward of the console. The ACM provides diagnostic information (DTCs) to the technician through the DRB III via the PCI bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp is driven with messages relayed to the Electro/Mechanical Instrument Cluster (EMIC) from the ACM via the PCI bus. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Whenever the ignition key is turned to the "run" or "start" position, the airbag control module performs a lamp check by turning the AIRBAG warning lamp ON for 6 - 8 seconds. If the lamp remains OFF, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains ON, there could be an active fault in the system or the circuit that operates the lamp may be shorted to ground. If the lamp comes ON and stays ON for a period longer than 6 - 8 seconds, then goes OFF, there is usually an intermittent problem in the system. WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. 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. - NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. Seat Belt Tensioner Front seat belt systems incorporate Tensioner Modules (SBT). At the onset of an impact event each tensioner uses a pyrotechnic device, which is triggered simultaneously with the airbags, to rapidly retract the seat belts. With the slack removed, the occupant's forward motion in an impact will be reduced as will the likelihood of contacting interior components. After an impact that deploys the airbag, the seat belt tensioner assembly must be replaced. The ACM module monitors the Seat Belt Tensioners circuit resistance and reports active and stored DTC's if any problem is found. Airbag Diagnostic Trouble Codes Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB III. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures, diagnostic trouble codes are used as a diagnostic tool. Active Codes The code becomes active as soon as the malfunction is detected and stored after one minute of occurrence or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 2610 of 12 seconds or as long as the malfunction is present. Stored Codes Airbag codes are automatically stored in the ACM's memory after one minute of occurrence or when the ignition is turned OFF. The exception is the "Loss of Ignition Run Only" code which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored as long as the malfunction exists. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, that diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "ON" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. AUDIO SYSTEM The factory installed radio receiver communicates on the Programmable Communication Interface (PCI) data bus network through a separate two-way wire harness connector. This is used for the remote radio switches that are mounted to the steering wheel, and also used for radio diagnosis with the DRB III. The remote radio switches are resistor multiplexed units that are hard wired to the CTM through the clockspring. The CTM monitors the status of the remote radio switches and sends the proper switch status messages on the PCI data bus network to the radio receiver. The electronic circuitry within the radio is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. When troubleshooting output shorts or "output" error messages, the following applies: On radios without an external amplifier, the term "output" refers to the path between the radio and the speaker. This type of circuit can be monitored all the way through the speaker connections by the radio assembly. When the radio displays a shorted output DTC with this type of system, the speaker, radio or wiring could be at fault. The output DTC could refer to a front or rear output or a left or right output. The reason for the difference is the pairing of the output sections of the radio. Some are paired left and right, others are paired front and rear. On radios with an external amplifier, the term "output" refers to the circuit between the radio connector and the amplifier. The radio is capable of monitoring only this portion and can tell nothing about the circuit between the amplifier and the speakers. Consequently, a shorted output DTC on this type of system would only refer to this circuit. A faulty speaker could not cause this DTC. CENTRAL TIMER MODULE The Durango (DN) utilizes a Central Timer Module (CTM). This system is available in a Base or Highline configuration. The CTM performs most of the typical functions a Body Control Module would perform. The Base and Highline CTM provides the following features: Battery Saver Functions For Exterior and Interior Lamps - Cargo Lamps - Chime Warning - Courtesy Lamps - Dome Lamps - Dome Defeat - Door Ajar Switch Status - Fog Lamps - Head Lamp Time Delay - Intermittent Wiper Controls - Low and High Beam Head Lamps - Optical Horn - Park Lamps Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 2611 Additional features of Highline CTM - Central Locking (VTSS) - Door Lock Inhibit - Driver Door Unlock - Enhanced Accident Response - Power Door Locks - Remote Radio - Remote Keyless Entry - Vehicle Theft Alarm (VTSS) The Central Timer Module is located behind the left side kick panel. It contains 26-way, 16-way and 12-way connectors. CHIME SYSTEM The chime system is built into the CTM. There are two chime rates, Low: 50 chimes per minute for reminders and High: 180 chimes per minute for serious conditions that require immediate attention. The high rate chime sounds when the key is left in the ignition and the driver's door is open or if the headlights or the courtesy lights are left on. The low rate chime sounds for any of the other conditions. There is a variable rate feature that allows the chime to sound continuously for key-in and headlamp warning as long as the door is open. The seat belt warning chime is activated for six seconds, and all other chime conditions will activate the chime once at the same time the warning light on the cluster is illuminated. The Chime will sound for the following conditions: Ignition OFF key in ignition, driver's door open - Ignition OFF, headlamps ON, driver's door open - Ignition OFF, courtesy lamps ON, driver's door open - Seat belt warning (after prove-out) - Malfunction Indicator lamp (MIL) illuminated (after prove-out) - Airbag lamp illuminated (after prove-out) - Check gauges lamp - Low fuel warning - Low washer fluid lamp - Door ajar warning - Transmission temperature lamp - Turn signal on reminder warning - Button pushed on compass mini-trip computer COMPASS MINI-TRIP COMPUTER (CMTC) This system, located in the overhead console, displays information on outside temperature, compass direction and trip information. Compass and Temperature Display This display provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. Trip Odometer (ODO) Shows the distance traveled since the last reset. Average Fuel Economy (AVE ECO) Shows the average fuel economy in MPG (miles per gallon) or L/100 Km since the last reset. Instant Fuel Economy Shows the fuel economy for the last few seconds in MPG or L/100 Km. Distance to Empty (DTE) Shows the estimated distance that can be traveled with the fuel remaining in the tank. This is calibrated using the MPG for the last few minutes. Elapsed Time (ET) Shows the accumulated ignition ON time since the last reset. Step Button Press this button to cycle through all the mini-trip computer displays. US/M Button Press this button to convert all vehicle displays from US to Metric to US. To Reset the Display Press the Step and US/M buttons simultaneously for at least two seconds and all resettable conditions will be reset. This will occur only if a resettable function (AVG ECO, ECO, ET) is currently being displayed. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 2612 Automatic Compass Calibration This compass is self calibrating which eliminates the need to manually set the compass. When the vehicle is new, the compass may appear erratic and the CAL symbol will be displayed. After completing three 360' turns in an area free from large metal or metallic objects, the CAL symbol will turn OFF and the compass will function normally. Compass Variance Compass Variance is the difference between Magnetic North and Geographic North. In some areas of the country, the difference between Magnetic and Geographic North is great enough to cause the compass to give false readings. If this occurs, the compass variance must be set. To Set the Variance Turn the ignition ON and set display to Comp./Temp. while pressing the US/M button, press the STEP button for approximately five seconds. The "VAR" symbol will light and the last variance zone number will be displayed. Press the US/Metric Button to select the proper variance zone as shown on the map. Press the Step button to set the new variance zone and resume normal operation. ELECTRO/MECHANICAL INSTRUMENT CLUSTER (EMIC) The Instrument Cluster contains a Fuel, Voltmeter, Coolant Temp, and Oil Pressure gauge, a Tachometer and a Speedometer. With the exception of the Voltmeter, the cluster positions the gauges with PCI Bus messages received from the PCM. The Voltmeter operates directly off of the Fused B+ Switched Ignition Output circuit that supplies ignition voltage for the cluster. The Instrument Cluster also contains warning indicators that are illuminated by hard wired inputs or by messages received from other modules on the PCI Bus. The Trip/Total Odometer is a Vacuum Fluorescent Display (VF) that is controlled by PCI Bus messages received from the PCM. The cluster illumination lamps are hard wired in the Instrument Cluster. When the Park or Headlamps are turned ON, the cluster receives a dimmed battery feed from the Headlamp Switch. The cluster I/O Processor controls the VF display dimming and also sends dimming level messages on the PCI Bus. The EMIC will communicate with the DRB III to display PCI Engine Info, PCI Bus Info, and certain input/outputs. Cluster diagnostic capabilities that the DRB III will actuate are limited to the Cluster Calibration Points for the gauges. The DRB III can also extract active and stored Diagnostic Trouble Codes (DTC) from the Instrument Cluster. The EMIC is also capable of performing a diagnostic Self-Test that is actuated by depressing and holding the Odometer trip reset stalk while cycling the ignition from the OFF to the ON position. After the cluster Odometer displays CHEC, releasing the reset stalk begins the test. The cluster will then position all of the gauges at specified calibration points and will illuminate all the PCI Bus controlled indicators. The cluster will also illuminate each segment of the VF display. The EMIC can verify communications with the PCM, ID the module, or change the country code using the DRB III. ENHANCED ACCIDENT RESPONSE (HIGHLINE CTM ONLY) If the Airbag Control Module (ACM) deploys the airbags, a message is transmitted over the PCI bus to the CTM module to unlock the doors. The interior lights will be turned ON when the vehicle speed message on the PCI bus indicates 0 mph or the message is not present. In addition to unlocking the doors, the door lock feature will be disabled for a predetermined amount of time following the deployment. Once the ignition key has been cycled to the "OFF" position, normal operation will resume. EXTERIOR LIGHTING The low and high beam headlamps are controlled directly by an output from the Central Timer Module (CTM). The park lamps and fog lamps (on vehicle so equipped) are controlled via external relays that are energized by the CTM. The headlamp switch provides the control signal through the multifunction switch to the CTM, which indicates low or high beam operation. The Optical Horn (Flash to Pass) feature operates both the high beam and low beam headlamps. The CTM provides the Headlamp Time Delay feature. To start the delay, turn the ignition OFF while the headlamps are ON. Then turn the headlamp switch to the OFF position. This has to be done within 45 seconds of the ignition being turned OFF. The headlamps will remain ON for 60 ± 5 seconds. If during this delay period the headlamp switch is turned ON and then OFF, or ignition switch is turned ON delay will be canceled and they will turn OFF immediately. During the delay period, only headlamps are turned ON and park lamps/fog lamps are turned OFF. The CTM also provides battery protection to avoid wearing down the battery if the customer leaves the park lamps or headlamps ON for extended period of time with the ignition OFF. If the park lamps or headlamps remain ON for more than 5 minutes while the ignition is OFF, the headlamps and park lamps shall be turned off and the input causing the lamps to be ON will be ignored until the input is corrected. Once the 5 minute timeout has extinguished the headlamps and park lamps, any change in the ignition switch, door ajar switches, headlamps switch or park lamp switch will reset the 5 minute timer and return the headlamps and park lamps to normal operation. Part 2 of 2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 2613 HEATING & A/C SYSTEM The all-new heating and air conditioning system for DN provides more heating and cooling capacity than in previous years. Depending on the model, either a Dual-Zone Air Conditioning System or a Three-Zone Air Conditioning System is currently available in these vehicles. Air Distribution (Front) The front compartment HVAC unit has four fully adjustable instrument panel outlets. Side-window demister outlets in the instrument panel eliminate the need for door ducts and door-to-instrument panel seals. A single central mounted outlet delivers air for defrosting the windshield. Two outlets, one on each side of the center console underneath the instrument panel, provide airflow to the driver floor area and to the front seat passenger floor area. While two additional outlets, one on each side of the center console near the rear of the front seats, distribute both heated and cooled air across the floor to the intermediate seat passengers. Ducts in the center of the vehicle underneath the carpet deliver air from the front compartment HVAC unit to the two intermediate passenger outlets. Door Actuator Control A simplified control system for operation of the mode, recirculation, and temperature control actuators provides positive positioning without the complexity of feedback from position sensors. The A/C - Heater Control Module knows the number of operating actuator revolutions required for full door travel as well as the number of actuator commutator pulses per revolution. Using these parameters, the A/C - Heater Control Module runs the actuator for the number of commutator pulses that correspond to the desired door position. To maintain accuracy, the system recalibrates itself periodically at known zero and full travel conditions. The dual sliding Blend switches have multiple detents to control the full range of temperature that the system can produce in any mode. On Dual-Zone systems, the upper slide pot controls the driver-side blend door and the lower slide pot controls the passenger-side blend door. On Three-Zone systems, the upper slide pot controls the driver-side blend door, while the lower slide pot controls the passenger-side blend door and the rear A/C - heater unit blend door. The single rotary Mode switch has 12 detents to either direct airflow to the panel outlets, to a mix of floor and panel outlets, to the floor outlets, to a mix of floor and defrost outlets, or to the defrost outlet. Rotating the Mode switch to either of the two MAX positions results in the A/C - Heater Control Module sending a signal to the recirculation actuator to close the fresh-air door. While rotating the Mode switch to any other position results in the A/C - Heater Control Module sending a signal to the recirculation actuator to open the fresh-air door. When the Blower switch is OFF, the A/C - Heater Control Module closes the fresh-air door to prevent outside air from entering the vehicle. On Three- Zone systems, the Mode switch also controls the rear A/C - heater unit mode door, which directs rear airflow either to the right quarter trim panel outlet or to the overhead outlets. Front Blower Control The front blower circuitry employs a new resistor technology to control front blower speed. Called the "credit card" resistor, the device looks much like its name in that it is thin and compact like a credit card. The credit card resistor, like the coil resistor used in previous years, mounts inside the front HVAC housing assembly in the airflow path. However, unlike the coil resistor, the credit card resistor offers much less airflow restriction. A/C Operation The A/C - Heater Control Module monitors the temperature of the evaporator to keep it just above freezing for maximum cooling and dehumidification. A thermistor (temperature variable resistor) placed between the evaporator fins provides the signal for the control. The Powertrain Control Module (PCM) cycles the compressor on and off with a signal from the A/C - Heater Control Module. Heater Operation To assist the HVAC system in maintaining a consistent and optimum heat output at low vehicle speeds, an electric coolant pump operates under specific conditions to keep a steady flow of hot coolant circulating through the heater circuit. The A/C - Heater Control Modules controls the operation of the electric coolant pump. The pump runs when all of the following conditions are met: When the vehicle's speed is below 27 Km/h (17 mph), the coolant temperature is between 65.5 °C and 110 °C (150 °F and 230 °F), and the blend control is set above 60% reheat. The A/C - Heater Control Module turns the pump OFF if any one of the following conditions occur: The vehicle speed rises above 48.3 Km/h (30 mph). The coolant temperature drops below 65.5 °C (150 °F). The coolant temperature rises above 110 °C (230 °F). The blend control is set below 60% reheat. A/C - Heater Control (Rear) The Three-Zone system allows the intermediate seat occupants to regulate the air temperature and the fan speed of the rear unit from the rotary controls on the headliner mounted Rear A/C - Heater Control. HVAC Diagnostics The A/C - Heater Control Module is fully addressable with the DRB III. Two of the Control Module's diagnostic capabilities that the DRB III will actuate include the A/C Cool down Test to test A/C system performance and the HVAC Door Recalibration Test to determine actuator travel span. After performing either test, the Control Module will display one or more messages on the DRB III screen. The message will indicate either that the HVAC system passed the test or that there is a fault currently active in the HVAC system. The DRB III can also extract active and stored Diagnostic Trouble Codes (DTCs) from the control module. Active DTCs are faults that currently exit in the HVAC system. Stored DTCs are faults that occurred in the HVAC system since the control module received the last "clear diagnostic info" message. INTERIOR LIGHTING Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 2614 The Courtesy lights and illuminated entry feature are controlled by the Central Timer Module (CTM). The CTM will activate the courtesy lamps, including Map Lights and the Dome Lights when either the dome lamp switch is turned ON or a door is opened. The courtesy lamps will fade to OFF immediately when all doors are closed with the dome lamp switch in the OFF position. The illuminated entry feature operates under the following conditions: RKE "unlock" - Driver/Passenger door is opened - Unlocking either the driver or passenger using the key (vehicles equipped with security system) - The dome lamp switch is turned ON Once activated, the illuminated entry will "fade to OFF" after 3 to 5 seconds under the following conditions: All doors are closed and: RKE "lock signal is received or - Manual actuated power "lock" signal is received or - Ignition switch is turned to the ON position or - 30 seconds have elapsed without any other action Addition RKE unlock actuation before the expiration of illuminated entry will not reset timer. Opening any door before the 30 second timer expires, will reset the entry time to 30 seconds and the illuminated entry timer will not begin counting down again until all doors are closed. The Cargo lamps are controlled by the CTM. Placing the dome lamp switch in the cargo lamp position grounds an input to the CTM. The CTM then sends voltage to the cargo lamps. The Interior lamp defeat feature will not allow any interior lamp to be turned ON. This is accomplished through an input to the CTM from the dome lamp switch. The CTM provides battery protection by shutting down the interior lamps due to the following. Leaving a door open, dome lamp switch ON, reading/vanity lamp switch ON or glove box door open for more than 15 minutes while the ignition is OFF. POWER DOOR LOCKS/REMOTE KEYLESS ENTRY The CTM controls the door lock actuator assemblies to handle locking and unlocking with the key fob or interior switch. Vehicles that are equipped with the Vehicle Theft Security System will also have the central locking feature. With the central locking feature, when the cylinder lock switch is turned to the lock position all the doors will lock. For unlocking, if the key is turned to the unlock position once, only that door will unlock. If the key is then turned a second time to the unlock position, all the doors will unlock. There is also a door lock inhibit feature that prevents power locking of the doors if the ignition is OFF and the key is in the ignition. Automatic or "rolling locks" are included as a programmable feature. If the vehicle is moving approximately 15 mph and approximately 10 degrees of throttle opening is seen by the PCM, (the PCM will send this info to the CTM via the PCI bus) indicating acceleration, the CTM will cycle the lock actuators to lock the doors. The highline CTM provides for Remote Keyless Entry (RKE) The RKE system is placed in the programming mode by the DRB III, or by the customer program features. The system will store up to four key fob codes. Two fobs are supplied with the truck, additional fobs may be purchased through the parts department. Through the DRB III, erasing and programming of one key fob without deleting the others is possible. If the key fob is stolen, all the fob codes stored previously may be erased to provide the owner of the vehicle with an extra sense of security. VEHICLE COMMUNICATION The Programmable Communication Interface or PCI Bus is a single wire multiplexed network capable of supporting binary encoded messages shared between multiple modules. The PCI bus circuit is identified as D25 and is violet with a yellow tracer. Additional tracer colors may be added to the yellow in order to distinguish between different module connections. The modules are wired in parallel. Connections are made in the harness using a splice. The splice called the Diagnostic Junction Port, serves as the "Hub" of the bus. The Diagnostic Junction Port provides an access point to isolate most of the modules on the bus in order to assist in diagnosing the circuit. The following modules are used on the DN: Airbag Control Module - A/C Heater Control - Central Timer Module - Controller Antilock Brake - Compass Mini-Trip Computer - Electro/Mechanical Instrument Cluster - Powertrain Control Module - Radio Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 2615 - Sentry Key Immobilizer Module - Transfer Case Control Module - Transmission Control Module Each module provides its own bias and termination in order to transmit and receive messages. The bus voltage is at zero volts when no modules are transmitting and is pulled up to about seven and a half volts when modules are transmitting. The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRB III lab scope. The 12v square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between zero and about seven and a half volts. Refer to the figure for some typical displays. The PCI Bus failure modes are broken down into two categories. Complete PCI Bus Communication Failure and individual module no response. Causes of complete PCI Bus Communication Failure include a short to ground or battery on the PCI circuit. Individual module no response can be caused by an open circuit at either the Diagnostic Junction Port or the module, or an open battery or ground circuit to the affected module. Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: All gauges on the EMIC stay at zero - All telltales on EMIC illuminate - EMIC backlighting at full intensity - Dashed lines in the Compass Mini-Trip Computer display Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 2616 - No response received from any module on the PCI bus (except the PCM) - No start (if equipped with Sentry Key immobilizer) Symptoms of Individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRB III. Diagnosis starts with symptom identification. If a complete PCI Bus Communication Failure is suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRB III. If any modules are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI circuit or power supply and ground circuits. The DRB III may display "BUS +A SIGNAL OPEN" or "NO RESPONSE" to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRB III and in no way indicates whether or not the PCI bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped. VEHICLE THEFT SECURITY SYSTEM The VTSS system monitors the door ajar switches, and ignition switch to detect unauthorized entry into the vehicle. Once the vehicle is "armed", any one of these inputs can cause the VTSS system to be tripped. Once tripped, the horn and lights will pulse for 3 minutes and if an attempt is made to start the engine with a non-programmed SKIM key, it will start and stall. If the trigger condition is still present, the lights will continue to flash for an additional 15 minutes, after which the system will stop pulsing the lights and return to the "armed" state. The cause of the last 4 alarm triggers is stored by the CTM and may be retrieved by the DRB III. The system may be disarmed by either an unlock command from a valid RKE key fob by using a key in either door, or by using a valid SKIM key in the ignition. The door key cylinders are equipped with disarm switches. There is also a VTSS lamp on the dash that provides information to the driver about the state of the vehicle theft system. WINDSHIELD WIPER SYSTEM The DN truck is equipped with speed sensitive intermittent wipers. The low and high speeds are controlled through the wiper stalk switch. The intermittent portion of the wiper control is handled by the CTM through the intermittent wiper relay. When the module detects a decrease in delay time as selected by the driver, an immediate wipe of the windshield takes place and the new delay interval is implemented. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Central Timer Module: Symptom Related Diagnostic Procedures Non-Trouble Code Procedures For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. The hard wired inputs to and outputs from the Central Timer Module (CTM) may be diagnosed and tested using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the CTM. In order to obtain conclusive testing of the CTM, the Programmable Communications Interface (PCI) data bus network and all of the electronic modules that provide inputs to or receive outputs from the CTM must also be checked. The most reliable, efficient, and accurate means to diagnose the CTM, the PCI data bus network, and the electronic modules that provide inputs to or receive outputs from the CTM requires the use of a DRB III scan tool. Refer to the appropriate diagnostic information. The DRB III scan tool can provide confirmation that the PCI data bus network is functional, that all of the electronic modules are sending and receiving the proper messages over the PCI data bus, and that the CTM is receiving the proper hard wired inputs and responding with the proper hard wired outputs needed to perform its many functions. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: The following tests may not prove conclusive in the diagnosis of the Central Timer Module (CTM). The most reliable, efficient, and accurate means to diagnose the CTM requires the use of a DRB III scan tool. Refer to the appropriate diagnostic information. 1. Check the fused B(+) fuses (Fuse 3 - 20 ampere, and Fuse 12 - 20 ampere) in the Power Distribution Center (PDC). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fused B(+) fuses (Fuse 3 - 20 ampere, and Fuse 12 - 20 ampere) in the PDC. If OK, go to Step 3. If not OK, repair the open B(+) circuit between the PDC and the battery as required. 3. Disconnect and isolate the battery negative cable. Disconnect the instrument panel wire harness connector (Connector C3) for the CTM from the CTM connector receptacle. Reconnect the battery negative cable. Check for battery voltage at each of the two fused B(+) circuit cavities of the instrument panel wire harness connector (Connector C3) for the CTM. If OK, disconnect and isolate the battery negative cable, reconnect the instrument panel wire harness connector (Connector C3) for the CTM to the CTM connector receptacle, and go to Step 4. If not OK, repair the open fused B(+) circuit(s) between the CTM and the PDC as required. 4. Check the fused ignition switch output (run-start) fuse (Fuse 11 - 10 ampere) and the fused ignition switch output (run-acc) fuse (Fuse 5 - 20 ampere) in the Junction Block (JB). If OK, go to Step 5. If not OK, repair the shorted circuit or component as required and replace the faulty fuse(s). 5. Reconnect the battery negative cable. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run-start) fuse (Fuse 11 - 10 ampere) and the fused ignition switch output (run-acc) fuse (Fuse 5 20 ampere) in the JB. If OK, go to Step 6. If not OK, repair the open fused ignition switch output (run-start) circuit or fused ignition switch output (run-acc) circuit between the JB and the ignition switch as required. 6. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the instrument panel wire harness connector (Connector C1) for the CTM from the CTM connector receptacle. Reconnect the battery negative cable. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run-start) circuit cavity and the fused ignition switch output (run-acc) cavity of the instrument panel wire harness connector (Connector C1) for the CTM. If OK, go to Step 7. If not OK, repair the open fused ignition switch output (run-start) circuit or fused ignition switch output (run-acc) circuit between the CTM and the JB as required. 7. Turn the ignition switch to the OFF position. Check for continuity between each of the three ground circuits in the instrument panel wire harness connector (Connector C1) for the CTM and a good ground. In each case there should be continuity. If OK, use a DRB III scan tool to perform further diagnosis of the CTM. Refer to the appropriate diagnostic information. If not OK, repair the open ground circuit(s) to ground (G207 or G208) as required. Chime Inoperative At All Times Test 1 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2619 SYMPTOM CHIME INOPERATIVE AT ALL TIMES POSSIBLE CAUSES - CTM - Chime inoperative Chime Inoperative With Drivers Seat Belt Unfastened Tests 1 - 4 SYMPTOM CHIME INOPERATIVE WITH DRIVER SEAT BELT UNFASTENED POSSIBLE CAUSES - Seat belt switch status wrong - Seat belt switch shorted - Seat belt indicator driver wire short to ground - Instrument cluster - seat belt switch shorted Chime Inoperative With Key In Ignition and Driver's Door Open Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2620 Tests 1 - 4 Test 5 SYMPTOM CHIME INOPERATIVE WITH KEY IN IGNITION, DRIVER'S DOOR OPEN POSSIBLE CAUSES - Driver door ajar status - Ignition switch ground circuit open - Key-in ignition switch open - Key-in ignition switch sense circuit open - Central timer module Chime Inoperative, Exterior/Interior Lamps On, Driver Door Open Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2621 Tests 1 - 2 SYMPTOM CHIME INOPERATIVE WITH EXTERIOR OR INTERIOR LAMPS ON WITH DRIVER DOOR OPEN POSSIBLE CAUSES - DRB check driver door ajar - CTM-chime inoperative with headlamp switch - Operation of exterior or interior lighting system Chime Sounds With Driver Seat Belt Fastened Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2622 Tests 1 - 4 Test 5 SYMPTOM CHIME SOUNDS WITH DRIVER SEAT BELT FASTENED POSSIBLE CAUSES - Seat belt switch status wrong - Seat belt switch open - Ground wire open - Seat belt indicator driver wire open - Instrument cluster - seat belt sense open Chime Sounds With Drivers Door Open and Key Removed From Ignition Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2623 Tests 1 - 4 SYMPTOM CHIME SOUNDS WITH DRIVER'S DOOR OPEN, KEY REMOVED POSSIBLE CAUSES - Operation of exterior or interior lighting system - Key-in ignition switch shorted - Key-in ignition SW sense short to ground - Central timer module - key-in ignition shorted Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2624 Central Timer Module: Component Tests and General Diagnostics Road Testing A Complaint Vehicle ROAD TEST WARNINGS Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the test drive, do not try to read the DRB III screen while in motion. Do not hang the DRB III from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB III. Six Step Troubleshooting Procedure SIX-STEP TROUBLESHOOTING PROCEDURE Diagnosis is done in six basic steps: 1. Verification of complaint 2. Verification of any related symptoms 3. Symptom analysis 4. Problem isolation 5. Repair of isolated problem 6. Verification of proper operation Vehicle Preparation For Testing VEHICLE PREPARATION FOR TESTING Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2625 Central Timer Module: Scan Tool Testing and Procedures DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB III will display one of only two error messages: User-Requested WARM Boot (Press MORE and NO at the same time) User-Requested COLD Boot (Press MORE and YES at the same time) If the DRB III should display any other error message, record the entire display and call the S.T.A.R. Center for information and assistance. DRB III DOES NOT POWER UP If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB III. If all connections are proper between the DRB III and the vehicle or other devices, and the vehicle battery is fully charged, and inoperative DRB III may be the result of faulty cable or vehicle wiring. For a blank screen, refer to the appropriate body diagnostics. DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition SOME DISPLAY ITEMS READ "---" This is caused by scrolling the DRB III display a single line up or down. The line which was scrolled onto the screen might read "---". Use the Page Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2626 Down or Page Up function to display the information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Page 2627 Central Timer Module: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: Before replacing a Central Timer Module (CTM), use a DRB III scan tool to retrieve the current settings for the CTM programmable features. Refer to the appropriate diagnostic information. These settings should be duplicated in the replacement CTM using the DRB III scan tool before returning the vehicle to service. 1. Disconnect and isolate the battery negative cable. 2. Remove the trim from the left cowl side inner panel. Fig. 2 Central Timer Module 3. Disconnect the two instrument panel wire harness connectors and one body wire harness connector from the CTM connector receptacles. 4. Remove the three screws that secure the CTM to the left cowl side inner panel. 5. Remove the CTM from the left cowl side inner panel. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: Before replacing a Central Timer Module (CTM), use a DRB III scan tool to retrieve the current settings for the CTM programmable features. Refer to the appropriate diagnostic information. These settings should be duplicated in the replacement high-line/premium CTM using the DRB III scan tool before returning the vehicle to service. 1. Position the CTM onto the left cowl side inner panel. 2. Install and tighten the three screws that secure the CTM to the left cowl side inner panel. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the two instrument panel wire harness connectors and one body wire harness connector to the CTM connector receptacles. 4. Reinstall the trim onto the left cowl side inner panel. 5. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Page 2628 Central Timer Module: Tools and Equipment DRB III (Diagnostic Read-out Box) Jumper Wires Ohmmeter Voltmeter Test Light Diagnostic Junction Port Tester 8310 Airbag Load Tool 8443 Airbag Load Tool Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Customer Interest: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts Powertrain Control Module: Customer Interest A/T - 45RFE/545RFE Harsh Upshifts/Downshifts NUMBER: 18-025-01 GROUP: Vehicle Performance DATE: October 15, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-09-00, DATED SEPTEMBER 15, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. **ASTERISKS** HAVE BEEN USED TO HIGHLIGHT CHANGES. THIS BULLETIN ADDS A MODEL YEAR AND REQUIRES A REPROGRAMMING OF THE 1999 AND 2000 GRAND CHEROKEE POWERTRAIN CONTROL MODULE (PCM). SUBJECT: 45RFE **and 545RFE Shift** Quality Enhancements for the** 2-3, 4-5, and 5-4** Shifts OVERVIEW: This bulletin involves selectively erasing and reprogramming the **Transmission Control Module (TCM) with new software: '99-'01 WJ (PN 05019701AC Ver 9.3), '00 AN/DN (PN 05018454AB Ver 9.1), or '01 AN/DN (PN 56028285A1 Ver 8.4), and requires reprogramming of the Powertrain Control Module (PCM) for the 1999 and 2000 Grand Cherokees only (with calibration 99Cal20 (1999) or 00Cal17 (2000).** NOTE: THE 2001 GRAND CHEROKEE DOES NOT REQUIRE REPROGRAMMING OF THE PCM AS IT IS ALREADY AT THE CORRECT CALIBRATION LEVEL. NOTE: WHENEVER A PCM OR TCM IS REPLACED OR REPROGRAMMED, THE SOFTWARE OF THE PCM MUST BE VERIFIED AS HAVING THE LATEST REVISION LEVEL. MODELS: 2000 (AN) Dakota **2001** 2000 (DN) Durango **2001** 1999 (WJ) Grand Cherokee **2001 ** NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 4.7L ENGINE AND A 45RFE **OR 545RFE** TRANSMISSION. SYMPTOM/CONDITION: Some vehicles **may exhibit one or more of the following performance conditions **: 1. A harsh 2-3 upshift causing a powertrain clunk or shudder when accelerating. 2. **A harsh 4-5 upshift ('01 Grand Cherokee only).** 3. **A harsh 5-4 downshift ('01 Grand Cherokee only).** NOTE: THIS REVISION TO THE TCM SOFTWARE ADDRESSES THE ABOVE SHIFT QUALITY CONDITIONS FOR ALL VEHICLES AND, ADDS A FINAL GEAR RATIO TO THE **1999 AND 2000 MY** GRAND CHEROKEE TRANSMISSION ONLY. (2001 MY GRAND CHEROKEE ALREADY HAS THIS UPGRADE.) NOTE: TO MAINTAIN EMISSIONS COMPLIANCE, GRAND CHEROKEE VEHICLES THAT ARE EQUIPPED WITH A FEDERAL EMISSION SYSTEM (SALES CODE NAA) MUST HAVE THEIR PCM REPROGRAMMED. IF THE SOFTWARE LEVEL IS AT OR HIGHER THAN THOSE IN THE OVERVIEW ABOVE, OR IF THE GRAND CHEROKEE HAS A CALIFORNIA EMISSIONS SYSTEM (SALES CODE NAE), REPROGRAMMING IS NOT NECESSARY. DIAGNOSIS PROCEDURES: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRBIII(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 performing this repair. If no DTC's are present, and the above symptom has been experienced, perform the Repair Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Customer Interest: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts > Page 2637 Procedure. NOTE: **IF OTHER PERFORMANCE ISSUES REMAIN AFTER THE REPAIR PROCEDURE HAS BEEN PERFORMED THEY DO NOT RELATE TO THIS BULLETIN. REFER TO THE PROPER SERVICE OR DIAGNOSTIC PROCEDURES MANUAL(S) FOR FURTHER ASSISTANCE.** PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD **2093 OR HIGHER AND DRB III(R) VERSION 52.3 WILL BE IN THE DEALERSHIPS ON OCTOBER 15, 2001.)** REPAIR PROCEDURE: 1. Log onto the MDS2 (Mopar Diagnostic System). 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III(R), MDS2, AND VEHICLE ESTABLISH COMMUNICATION. 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. 3. Push the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) 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. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. 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, 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 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Customer Interest: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts > Page 2638 7. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 8. 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > All Technical Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Powertrain Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > All Technical Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2644 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > All Technical Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2645 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > All Technical Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2646 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > All Technical Service Bulletins for Powertrain Control Module: > 18-025-01 > Oct > 01 > A/T 45RFE/545RFE Harsh Upshifts/Downshifts Powertrain Control Module: All Technical Service Bulletins A/T - 45RFE/545RFE Harsh Upshifts/Downshifts NUMBER: 18-025-01 GROUP: Vehicle Performance DATE: October 15, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-09-00, DATED SEPTEMBER 15, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. **ASTERISKS** HAVE BEEN USED TO HIGHLIGHT CHANGES. THIS BULLETIN ADDS A MODEL YEAR AND REQUIRES A REPROGRAMMING OF THE 1999 AND 2000 GRAND CHEROKEE POWERTRAIN CONTROL MODULE (PCM). SUBJECT: 45RFE **and 545RFE Shift** Quality Enhancements for the** 2-3, 4-5, and 5-4** Shifts OVERVIEW: This bulletin involves selectively erasing and reprogramming the **Transmission Control Module (TCM) with new software: '99-'01 WJ (PN 05019701AC Ver 9.3), '00 AN/DN (PN 05018454AB Ver 9.1), or '01 AN/DN (PN 56028285A1 Ver 8.4), and requires reprogramming of the Powertrain Control Module (PCM) for the 1999 and 2000 Grand Cherokees only (with calibration 99Cal20 (1999) or 00Cal17 (2000).** NOTE: THE 2001 GRAND CHEROKEE DOES NOT REQUIRE REPROGRAMMING OF THE PCM AS IT IS ALREADY AT THE CORRECT CALIBRATION LEVEL. NOTE: WHENEVER A PCM OR TCM IS REPLACED OR REPROGRAMMED, THE SOFTWARE OF THE PCM MUST BE VERIFIED AS HAVING THE LATEST REVISION LEVEL. MODELS: 2000 (AN) Dakota **2001** 2000 (DN) Durango **2001** 1999 (WJ) Grand Cherokee **2001 ** NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 4.7L ENGINE AND A 45RFE **OR 545RFE** TRANSMISSION. SYMPTOM/CONDITION: Some vehicles **may exhibit one or more of the following performance conditions **: 1. A harsh 2-3 upshift causing a powertrain clunk or shudder when accelerating. 2. **A harsh 4-5 upshift ('01 Grand Cherokee only).** 3. **A harsh 5-4 downshift ('01 Grand Cherokee only).** NOTE: THIS REVISION TO THE TCM SOFTWARE ADDRESSES THE ABOVE SHIFT QUALITY CONDITIONS FOR ALL VEHICLES AND, ADDS A FINAL GEAR RATIO TO THE **1999 AND 2000 MY** GRAND CHEROKEE TRANSMISSION ONLY. (2001 MY GRAND CHEROKEE ALREADY HAS THIS UPGRADE.) NOTE: TO MAINTAIN EMISSIONS COMPLIANCE, GRAND CHEROKEE VEHICLES THAT ARE EQUIPPED WITH A FEDERAL EMISSION SYSTEM (SALES CODE NAA) MUST HAVE THEIR PCM REPROGRAMMED. IF THE SOFTWARE LEVEL IS AT OR HIGHER THAN THOSE IN THE OVERVIEW ABOVE, OR IF THE GRAND CHEROKEE HAS A CALIFORNIA EMISSIONS SYSTEM (SALES CODE NAE), REPROGRAMMING IS NOT NECESSARY. DIAGNOSIS PROCEDURES: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRBIII(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 performing this repair. If no DTC's are present, and the above symptom has been experienced, perform the Repair Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > All Technical Service Bulletins for Powertrain Control Module: > 18-025-01 > Oct > 01 > A/T 45RFE/545RFE Harsh Upshifts/Downshifts > Page 2651 Procedure. NOTE: **IF OTHER PERFORMANCE ISSUES REMAIN AFTER THE REPAIR PROCEDURE HAS BEEN PERFORMED THEY DO NOT RELATE TO THIS BULLETIN. REFER TO THE PROPER SERVICE OR DIAGNOSTIC PROCEDURES MANUAL(S) FOR FURTHER ASSISTANCE.** PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD **2093 OR HIGHER AND DRB III(R) VERSION 52.3 WILL BE IN THE DEALERSHIPS ON OCTOBER 15, 2001.)** REPAIR PROCEDURE: 1. Log onto the MDS2 (Mopar Diagnostic System). 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III(R), MDS2, AND VEHICLE ESTABLISH COMMUNICATION. 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. 3. Push the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) 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. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. 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, 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 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > All Technical Service Bulletins for Powertrain Control Module: > 18-025-01 > Oct > 01 > A/T 45RFE/545RFE Harsh Upshifts/Downshifts > Page 2652 7. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 8. 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > All Other Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Powertrain Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > All Other Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2658 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > All Other Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2659 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > All Other Service Bulletins for Powertrain Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2660 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2661 Powertrain Control Module: Specifications Powertrain Control Module Mounting Screws ................................................................................................................................. 3-5 Nm (30-40 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2662 Powertrain Control Module: Locations Powertrain Control Module Fig. 9 PCM Location The Powertrain Control Module (PCM) is located in the engine compartment. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2665 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2666 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2667 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2668 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2669 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2670 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2671 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2672 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2673 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2674 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2675 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2676 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2677 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2678 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2679 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2680 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2681 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2682 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2683 Powertrain Control Module: Connector Views Powertrain Control Module C1 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2684 Powertrain Control Module C2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2685 Powertrain Control Module C3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2686 Powertrain Control Module: Electrical Diagrams System Diagrams Refer to Powertrain Management/Diagrams/Electrical for wiring diagrams. See: Diagrams/Electrical Diagrams PCM Communication System Schematic Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2687 2001 Dodge JTEC System Federal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2688 2001 Dodge JTEC System California Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Page 2689 Powertrain Control Module: Description and Operation Fig. 9 PCM Location POWERTRAIN CONTROL MODULE The Powertrain Control Module (PCM) is located in the engine compartment. The PCM is referred to as JTEC. The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. NOTE: PCM Inputs: A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - Auto shutdown (ASD) sense - Battery temperature - Battery voltage - Brake switch - CCD bus (+) circuits - CCD bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for DRB scan tool - Engine coolant temperature sensor - Fuel level - Generator (battery voltage) output - Ignition circuit sense (ignition switch in ON/OFF/crank/run position) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Page 2690 - Intake manifold air temperature sensor - Leak detection pump (switch) sense (if equipped) - Manifold Absolute Pressure (MAP) sensor - Oil pressure - Output shaft speed sensor - Overdrive/override switch - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transmission governor pressure sensor - Transmission temperature sensor - Vehicle speed inputs from ABS or RWAL system NOTE: PCM Outputs: A/C clutch relay - Auto shutdown (ASD) relay - CCD bus (+A) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Generator lamp (if equipped) - Idle Air Control (IAC) motor Ignition coil - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through CCD circuits. - Overdrive indicator lamp (if equipped) - Radiator cooling fan - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through CCD circuits. - Transmission convertor clutch circuit - Transmission 3-4 shift solenoid - Transmission relay - Transmission temperature lamp (if equipped) - Transmission variable force solenoid MODES OF OPERATION As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. For example, the PCM must calculate different injector pulse width and ignition timing for idle than it does for wide open throttle (WOT). The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (O2S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (O2S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to-1 part fuel. By monitoring the exhaust oxygen content through the O2S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise - Acceleration Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Page 2691 - Deceleration - Wide open throttle (WOT) - Ignition switch OFF The ignition switch ON, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. Ignition Switch (KEY-ON) Mode This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: The PCM pre-positions the idle air control (IAC) motor. - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the engine is operating or the starter motor is engaged. - The 02S sensor heater element is energized via the ASD relay. The 02S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. Engine Start-Up Mode This is an Open Loop mode. The following actions occur when the starter motor is engaged.The PCM receives inputs from: Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Starter motor relay - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector ON and OFF. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. Engine Warm-Up Mode This is an Open Loop mode. During engine warmup, the PCM receives inputs from: Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) - Park/neutral switch (gear indicator signal-auto.trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector ON and OFF. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the clutch relay. This is done if A/C has been selected by the vehicle operator and requested by the A/C thermostat. - When engine has reached operating temperature, the PCM will begin monitoring 02S sensor input. The system will then leave the warm-up mode and go into closed loop operation. Idle Mode When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: Air conditioning select signal (if equipped) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Page 2692 - Air conditioning request signal (if equipped) - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector ON and OFF. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio by varying injector pulse width.It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. Cruise Mode When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen (O2S) sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector ON and OFF. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control ('AC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil ON and OFF. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. Acceleration Mode This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. Deceleration Mode When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed sensor If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Page 2693 The PCM adjusts ignition timing by turning the ground path to the coil ON and OFF. Wide Open Throttle Mode This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal (in the distributor) During wide open throttle conditions, the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector ON and OFF. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil ON and OFF. ignition switch OFF Mode When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. 5 VOLT SUPPLIES Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. Primary 5-volt supply: supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5-volt supply: supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (if equipped with an RE automatic transmission). IGNITION CIRCUIT SENSE This circuit ties the ignition switch to the Power- train Control Module (PCM). The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Voltage ON the ignition input can be as low as 6 volts and the PCM will still function. Voltage is supplied to this circuit to power the PCM's 8-volt regulator and to allow the PCM to perform fuel, ignition and emissions control functions. POWER GROUND The Powertrain Control Module (PCM) has 2 main grounds. Both of these grounds are referred to as power grounds. All of the high-current, noisy, electrical devices are connected to these grounds as well as all of the sensor returns. The sensor return comes into the sensor return circuit, passes through noise suppression, and is then connected to the power ground. The power ground is used to control ground circuits for the following PCM loads: Generator field winding - Fuel injectors - Ignition coil(s) - Certain relays/solenoids - Certain sensors SENSOR RETURN The Sensor Return circuits are internal to the Powertrain Control Module (PCM). Sensor Return provides a low-noise ground reference for all engine control system sensors. Refer to Power Grounds for more information. SIGNAL GROUND Signal ground provides a low noise ground to the data link connector. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Page 2694 Powertrain Control Module: Service and Repair REMOVAL USE THE DRB SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. Fig. 10 PCM Location And Mounting The PCM is located in the engine compartment. To avoid possible voltage spike damage to the PCM, ignition key must be OFF and negative battery cable must be disconnected before unplugging PCM connectors. 1. Disconnect negative battery cable at battery. 2. Remove cover over electrical connectors. Cover snaps onto PCM. 3. Carefully unplug the three 32-way connectors from PCM. 4. Remove three PCM mounting bolts and remove PCM from vehicle. INSTALLATION USE THE DRB SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. 1. Install PCM and mounting bolts to vehicle. 2. Tighten bolts to 3-5 Nm (30-40 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 cover over electrical connectors. Cover snaps onto PCM. 6. Install battery cable. 7. Use the DRB scan tool to reprogram new PCM with vehicles original Identification Number (VIN) and original vehicle mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Auto Shut Down (ASD) Relay: Locations Power Distribution Center Automatic Shut Down Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2698 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2699 Auto Shut Down (ASD) Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2700 Automatic Shut Down Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2701 Auto Shut Down (ASD) Relay: Description and Operation AUTO SHUT DOWN RELAY PCM Output The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit ON and OFF. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. ASD Sense - PCM Input A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2702 Auto Shut Down (ASD) Relay: Testing and Inspection Fig. 1 ASD And Fuel Pump Relay Terminals - Type 1 Fig. 2 ASD And Fuel Pump Terminals - Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2703 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2704 Auto Shut Down (ASD) Relay: Service and Repair Fig. 3 Power Distribution Center (PDC) Location REMOVAL The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations Oxygen Sensor Relay: Locations Power Distribution Center Oxygen Sensor Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2708 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2709 Oxygen Sensor Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2710 Oxygen Sensor Downstream Heater Relay (California) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2711 Oxygen Sensor Relay: Description and Operation OXYGEN HEATER RELAY The oxygen (O2) sensor heater relay is located in the Powertrain Distribution Center (PDC). Refer to Oxygen Sensor for oxygen sensor relay information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2712 Oxygen Sensor Relay: Service and Repair Fig. 21 Power Distribution Center (PDC) REMOVAL The oxygen sensor heater relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The oxygen sensor heater relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Fig. 1 Battery Temperature Sensor Location The battery temperature sensor is located under vehicle battery and is attached to a mounting hole on battery tray. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2717 Battery Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2718 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and 02 sensor heater tests). Most OBD II monitors are disabled below 20 degrees F. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2719 Battery Temperature Sensor: Testing and Inspection Tests 1 - 2 SYMPTOM CHECKING THE AMBIENT/BATTERY TEMPERATURE SENSOR POSSIBLE CAUSES - Ambient/Battery temperature sensor - Ambient/Battery temperature sensor (Out Of Calibration) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2720 Battery Temperature Sensor: Service and Repair Fig. 1 Battery Temperature Sensor Location REMOVAL The battery temperature sensor is located under vehicle battery (Fig. 1) and is attached to a mounting hole on battery tray. 1. Remove battery. Refer to Battery for procedures. 2. Disconnect sensor pigtail harness from engine wire harness. Sensor pigtail harness is clipped to vehicle near its electrical connector. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION The battery temperature sensor is located under vehicle battery (Fig. 1) and is attached to a mounting hole on battery tray. 1. Feed pigtail harness through hole in top of battery tray and press sensor into top of battery tray. 2. Connect pigtail harness. 3. Install battery. Refer to Battery for procedures. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Brake Pressure Switch > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor ................................................................................................................... ................................................... 12 Nm (106 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2727 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2728 Camshaft Position Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2729 Camshaft Position Sensor: Description and Operation Fig. 4 CMP Location The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. Fig. 5 CMP Sensor And Tonewheel The CMP sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects notches located on a tonewheel. The tonewheel is located at the front of the camshaft for the right cylinder head. As the tonewheel rotates, the notches pass through the sync signal generator. The pattern of the notches (viewed counter-clockwise from front of engine) is: 1 notch, 2 notches, 3 notches, 3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2730 notches, 2 notches 1 notch, 3 notches and 1 notch. The signal from the CMP sensor 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2731 Camshaft Position Sensor: Service and Repair Fig. 7 CMP Location REMOVAL The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. It is easier to remove/install sensor from under vehicle. 1. Raise and support vehicle. 2. Disconnect electrical connector at CMP sensor. 3. Remove sensor mounting bolt. 4. Carefully pry sensor from cylinder head in a rocking action with two small screwdrivers. 5. Check condition of sensor O-ring. INSTALLATION The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. 1. Clean out machined hole in cylinder head. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into cylinder head with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder head. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in. lbs.) torque. 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications Engine Coolant Temperature (ECT) Sensor: Specifications Engine Coolant Temperature Sensor ....................................................................................................................................................... 11 Nm (96 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2735 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2736 Engine Coolant Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2737 Engine Coolant Temperature (ECT) Sensor: Description and Operation DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: ^ for engine coolant temperature gauge operation through CCD or PCI (J1850) ^ Communications ^ Injector pulse-width ^ Spark-advance curves ^ ASD relay shut-down times ^ Idle Air Control (IAC) motor key-on steps ^ Pulse-width prime-shot during cranking ^ 02 sensor closed loop times ^ Purge solenoid on/off times ^ EGR solenoid on/off times (if equipped) ^ Leak Detection Pump operation (if equipped) ^ Radiator fan relay on/off times (if equipped) ^ Target idle speed Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2738 Engine Coolant Temperature (ECT) Sensor: Service and Repair REMOVAL - 4.7L WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. The ECT sensor is located near the front of the intake manifold. 1. Partially drain cooling system. 2. Disconnect electrical connector from ECT sensor. 3. Remove sensor from intake manifold. INSTALLATION - 4.7L 1. Install sensor. 2. Tighten to 11 Nm (8 ft. lbs.) torque. 3. Connect electrical connector to sensor. 4. Replace any lost engine coolant. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt .............................................................................................................................................................. 28 Nm (21 Ft. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2742 Crankshaft Position Sensor: Locations Fig. 15 CKP Sensor Location The Crankshaft Position (CKP) sensor is located at the right-rear side of the engine cylinder block. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2743 Crankshaft Position Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2744 Crankshaft Position Sensor: Description and Operation Fig. 15 CKP Sensor Location The Crankshaft Position Sensor (CKP) is mounted into the right-rear side of the engine block. 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. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. Fig. 17 CKP Sensor Operation And Tonewheel Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2745 On this engine, a tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2746 Crankshaft Position Sensor: Service and Repair Fig. 19 CKP Sensor Location/Removal/Installation REMOVAL The Crankshaft Position (CKP) sensor is located at the right-rear side of the engine cylinder block. It is positioned and bolted into a machined hole in the engine block. 1. Disconnect CKP electrical connector at sensor. 2. Remove CKP mounting bolt. 3. Carefully pry sensor from cylinder block in a rocking action with two small screwdrivers. 4. Remove sensor from vehicle. 5. Check condition of sensor O-ring. INSTALLATION 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into engine block with a slight rocking action. Do not twist sensor into position as damage to O-ring may result CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 28 Nm (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations Fig. 7 Fuel Gauge Sending Unit Location - Typical Module The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module. The fuel pump module is located inside of fuel tank. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2750 Fuel Level Sensor: Description and Operation FUEL LEVEL SENDING UNIT / SENSOR The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation: A constant input voltage source of about 12 volts (battery voltage) is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2751 Fuel Level Sensor: Service and Repair REMOVAL Fig. 7 Fuel Gauge Sending Unit Location - Typical Module The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module. The fuel pump module is located inside of fuel tank. 1. Remove fuel tank. 2. Remove fuel pump module. 3. Unplug 4-way electrical connector. 4. Disconnect 2 sending unit wires at 4-way connector. The locking collar of connector must be removed before wires can be released from connector. Note location of wires within 4-way connector. Fig. 8 Fuel Gauge Sending Unit Lock Tab/Tracks Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2752 5. The sending unit is retained to pump module with a small lock tab and notch. Carefully push lock tab to the side and away from notch while sliding sending unit downward on tracks for removal. Note wire routing while removing unit from module. INSTALLATION The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module. The fuel pump module is located inside of fuel tank. 1. Position sending unit into tracks. Note wire routing. 2. Push unit on tracks until lock tab snaps into notch. 3. Connect 2 sending unit wires into 4-way connector and install locking collar. 4. Connect 4-way electrical connector to module. 5. Install fuel pump module. 6. Install fuel tank. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications Intake Air Temperature (IAT) Sensor: Specifications Intake Manifold Air TEMP. Sensor ........................................................................................................................................................ 28 Nm (20 Ft. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2756 Intake Air Temperature (IAT) Sensor: Locations Fig. 24 Intake Manifold Air Sensor Location The Intake Manifold Air Temperature (IAT) sensor is installed into the intake manifold plenum near the left side of the throttle body. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2757 Intake Air Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2758 Intake Air Temperature (IAT) Sensor: Description and Operation The 2-wire Intake Manifold Air Temperature (IAT) sensor is installed in the intake manifold with the sensor element extending into the air stream. The IAT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as intake manifold temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. The IAT sensor provides an input voltage to the Powertrain Control Module (PCM) indicating the density of the air entering the intake manifold based upon intake manifold temperature. At key-ON, a 5-volt power circuit is supplied to the sensor from the PCM. The sensor is grounded at the PCM through a low-noise, sensor-return circuit. The PCM uses this input to calculate the following: - Injector pulse-width - Adjustment of spark timing (to help prevent spark knock with high intake manifold air-charge temperatures) The resistance values of the IAT sensor is the same as for the Engine Coolant Temperature (ECT) sensor. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2759 Intake Air Temperature (IAT) Sensor: Service and Repair Fig. 24 Intake Manifold Air Sensor Location REMOVAL The Intake Manifold Air Temperature (IAT) sensor is installed into the intake manifold plenum near the left side of the throttle body. 1. Disconnect electrical connector from sensor. 2. Remove sensor from intake manifold. INSTALLATION 1. Install sensor into intake manifold. Tighten sensor to 28 Nm (20 ft. lbs.) torque. 2. Connect electrical connector to sensor. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications Manifold Absolute Pressure (MAP) Sensor: Specifications MAP Sensor Mounting Screws ............................................................................................................ ..................................................... 3 Nm (25 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2763 Manifold Absolute Pressure (MAP) Sensor: Locations Fig. 27 MAP And ECT Sensor Locations The MAP sensor is located on the front of the intake manifold. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2764 Manifold Absolute Pressure Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2765 Manifold Absolute Pressure (MAP) Sensor: Description and Operation The MAP sensor is located on the front of the intake manifold. An O-ring seals the sensor to the intake manifold. The MAP sensor is used as an input to the Powertrain Control Module (PCM). It contains a silicon based sensing unit to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When manifold absolute pressure (MAP) equals Barometric pressure, the pulse width will be at maximum. A 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5V and full scale is 4.5V. For a pressure swing of 0-15 psi, the voltage changes 4.0V To operate the sensor, it is supplied a regulated 4.8 to 5.1 volts. Ground is provided through the low-noise, sensor return circuit at the PCM. The MAP sensor input is the number one contributor to fuel injector pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or at a higher altitude, because the air density changes with altitude. It will also help to correct for varying barometric pressure. Barometric pressure and altitude have a direct inverse correlation; as altitude goes up, barometric goes down. At key-ON, the PCM powers up and looks at MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure (relative to altitude). Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key-on. The difference between current voltage and what it was at key-on, is manifold vacuum. During key-ON (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring a known good sensor. As the altitude increases, the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key-ON, the barometric pressure needs to be updated. Any time the PCM sees Wide Open Throttle (WOT), based upon Throttle Position Sensor (TPS) angle and RPM, it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor input to aid in calculating the following: - Manifold pressure - Barometric pressure - Engine load - Injector pulse-width - Spark-advance programs - Shift-point strategies (certain automatic transmissions only) - Idle speed - Decel fuel shutoff The MAP sensor signal is provided from a single piezoresistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As manifold pressure changes, the diaphragm moves causing the element to deflect, which stresses the silicone. When silicone is exposed to stress, its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally. The sensor also contains electronics that condition the signal and provide temperature compensation. The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; meaning as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg. Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is approximately 29.92 in Hg. For every 100 feet of altitude, barometric pressure drops 0.10 in. Hg. If a storm goes through it can change barometric pressure from what should be present for that altitude. You should know what the average pressure and corresponding barometric pressure is for your area. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2766 Manifold Absolute Pressure (MAP) Sensor: Service and Repair Fig. 27 MAP And ECT Sensor Locations REMOVAL The MAP sensor is located on the front of the intake manifold. An O-ring seals the sensor to the intake manifold. 1. Disconnect electrical connector at sensor. 2. Clean area around MAP sensor. 3. Remove 2 sensor mounting bolts. 4. Remove MAP sensor from intake manifold. INSTALLATION The MAP sensor is located on the front of the intake manifold. An O-ring seals the sensor to the intake manifold. 1. Clean MAP sensor mounting hole at intake manifold. 2. Check MAP sensor O-ring seal for cuts or tears. 3. Position sensor into manifold. 4. Install MAP sensor mounting bolts (screws). Tighten screws to 3 Nm (25 In. lbs.) torque. 5. Connect electrical connector. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams Engine Oil Pressure Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 2770 Oil Pressure Sensor: Description and Operation DESCRIPTION The 2-wire, electrical/mechanical engine oil pressure sensor (sending unit) is located in an engine oil pressure gallery. OPERATION The oil pressure sensor uses two circuits. They are: ^ A signal to the PCM relating to engine oil pressure ^ A sensor ground through the PCM's sensor return The oil pressure sensor returns a voltage signal back to the PCM relating to engine oil pressure. This signal is then transferred (bussed) to the instrument panel on a CCD bus circuit to operate the oil pressure gauge and the check gauges lamp. Ground for the sensor is provided by the PCM through a low noise sensor return. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 2771 Oil Pressure Sensor: Service and Repair REMOVAL 1. Disconnect the negative cable from the battery. 2. Raise vehicle on hoist. 3. Remove front splash shield. 4. Disconnect oil pressure sender wire (Fig. 107). 5. Remove the pressure sender (Fig. 107). INSTALLATION 1. Install oil pressure sender. 2. Connect oil pressure sender wire. 3. Install front splash shield. 4. Lower vehicle. 5. Connect the negative battery cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Oxygen Sensor .................................................................................................................................... .................................................... 30 Nm (22 Ft. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System Oxygen Sensor: Locations Engine Compartment/Exhaust System The upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. The right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System > Page 2777 Oxygen Sensor: Locations OBD-II Heated Oxygen Sensor Numbering Convention - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2778 Oxygen Sensor: Diagrams Oxygen Sensor 1/1 Upstream (California) Oxygen Sensor 1/2 Downstream (California) Oxygen Sensor 1/2 Downstream (Except California) Oxygen Sensor 2/1 Upstream (California) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2779 Oxygen Sensor 2/2 Downstream (California) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2780 Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2781 Oxygen Sensor Downstream Heater Relay (California) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2782 Oxygen Sensor: Service Precautions WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Application O(2) Sensor Configuration Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Application > Page 2785 Oxygen Sensor: Application and ID OBD-II Heated Oxygen Sensor Numbering Convention - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 2786 Oxygen Sensor: Description and Operation The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Depending on the emission package, the vehicle may use a total of either 2 or 4 sensors. NAA Emissions Package: Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2). With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. NAS or NAE Emissions Package: On this emissions package, 4 sensors are used: 2 upstream (referred to as 1/1 and 2/1) and 2 downstream (referred to as 1/2 and 2/2). With this emission package, the right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. An O2 sensor is a galvanic battery that provides the PCM with a voltage signal (0-1 volt) inversely proportional to the amount of oxygen in the exhaust. In other words, if the oxygen content is low, the voltage output is high; if the oxygen content is high the output voltage is low. The PCM uses this information to adjust injector pulse-width to achieve the 14.7-to-1 air/fuel ratio necessary for proper engine operation and to control emissions. The O2 sensor must have a source of oxygen from outside of the exhaust stream for comparison. Current O2 sensors receive their fresh oxygen (outside air) supply through the wire harness. This is why it is important to never solder an O2 sensor connector, or pack the connector with grease. Four wires (circuits) are used on each O2 sensor: a 12-volt feed circuit for the sensor heating element; a ground circuit for the heater element; a low-noise sensor return circuit to the PCM, and an input circuit from the sensor back to the PCM to detect sensor operation. Oxygen Sensor Heater Relay: If the vehicle is equipped with 4 oxygen sensors, a separate oxygen sensor relay is used to supply voltage to the sensor heating elements. This particular relay is used only for the 1/2 and 2/2 downstream sensors. Voltage for the other 2 sensor heating elements is supplied directly from the ASD relay. To avoid the large simultaneous current surge needed to operate all 4 sensors, power is delayed to the 2 downstream heater elements by the PCM for approximately 2 seconds. Oxygen Sensor Heater Elements: The O2 sensor uses a Positive Thermal Co-efficient (PTC) heater element. As temperature increases, resistance increases. At ambient temperatures around 70 °F, the resistance of the heating element is approximately 13.5 ohms on the this engine. As the sensor's temperature increases, resistance in the heater element increases. This allows the heater to maintain the optimum operating temperature of approximately 930 ° - 1100 °F (500 ° - 600 °C). Although the sensors operate the same, there are physical differences, due to the environment that they operate in, that keep them from being interchangeable. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation, the PCM monitors certain O2 sensor input(s) along with other inputs, and adjusts the injector pulse width accordingly. During Open Loop operation, the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. Upstream Sensor - Engine Equipped With 2 Sensors: The upstream sensor (1/1) provides an input voltage to the PCM. The input tells the PCM the oxygen content of the exhaust gas. The PCM uses this information to fine tune fuel delivery to maintain the correct oxygen content at the downstream oxygen sensor. The PCM will change the air/fuel ratio until the upstream sensor inputs a voltage that the PCM has determined will make the downstream sensor output (oxygen content) correct. The upstream oxygen sensor also provides an input to determine catalytic convertor efficiency. Downstream Sensor - Engine Equipped With 2 Sensors: The downstream oxygen sensor (1/2) is also used to determine the correct air-fuel ratio. As the oxygen content changes at the downstream sensor, the PCM calculates how much air-fuel ratio change is required. The PCM then looks at the upstream oxygen sensor voltage and changes fuel delivery until the upstream sensor voltage changes enough to correct the downstream sensor voltage (oxygen content). The downstream oxygen sensor also provides an input to determine catalytic convertor efficiency. Upstream Sensors - Engine Equipped With 4 Sensors: Two upstream sensors are used (1/1 and 2/1). The 1/1 sensor is the first sensor to receive exhaust gases from the # 1 cylinder. They provide an input voltage to the PCM. The input tells the PCM the oxygen content of the exhaust gas. The PCM uses this information to fine tune fuel delivery to maintain the correct oxygen content at the downstream oxygen sensors. The PCM will change the air/fuel ratio until the upstream sensors input a voltage that the PCM has determined will make the downstream sensors output (oxygen content) correct. The upstream oxygen sensors also provide an input to determine mini-catalyst efficiency. Main catalytic convertor efficiency is not calculated with this package. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 2787 Downstream Sensors - Engine Equipped With 4 Sensors: Two downstream sensors are used (1/2 and 2/2). The downstream sensors are used to determine the correct air-fuel ratio. As the oxygen content changes at the downstream sensor, the PCM calculates how much air-fuel ratio change is required. The PCM then looks at the upstream oxygen sensor voltage, and changes fuel delivery until the upstream sensor voltage changes enough to correct the downstream sensor voltage (oxygen content). The downstream oxygen sensors also provide an input to determine mini-catalyst efficiency. Main catalytic convertor efficiency is not calculated with this package. Engines equipped with either a downstream sensor(s), or a post-catalytic sensor, will monitor catalytic convertor efficiency. If efficiency is below emission standards, the Malfunction Indicator Lamp (MIL) will be illuminated and a Diagnostic Trouble Code (DTC) will be set. Refer to Monitored Systems in Emission Control Systems for additional information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 2788 Oxygen Sensor: Service and Repair REMOVAL Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. For sensor operation, it must have a comparison source of oxygen from outside the exhaust system. This fresh air is supplied to the sensor through its pigtail wiring harness. Fig. 28 Upstream Oxygen Sensor Locations Fig. 29 Downstream Oxygen Sensor Location Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 2789 Fig. 30 Pre-Catalyst/Post-Catalyst Oxygen Sensor Locations Fig. 31 Left/Right Oxygen Sensor Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 2790 Fig. 32 Oxygen Sensor Locations 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 O2S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove the O2S sensor with an oxygen sensor removal and installation tool. 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 O2S sensor. Tighten to 30 Nm (22 ft. lbs.) torque. 2. Connect the O2S sensor wire connector. 3. Lower the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications Power Steering Pressure Switch: Specifications Power Steering Pressure Switch ............................................................................................................................................... 14-22 Nm (124-195 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2794 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2795 Power Steering Pressure Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2796 Power Steering Pressure Switch: Description and Operation DESCRIPTION A pressure sensing switch is included in the power steering system (mounted on the high pressure line). This switch will be used only on vehicles equipped with a 4.7L V-8 engine and power steering. OPERATION The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high pump load and low engine rpm; such as during parking maneuvers. The PCM will then increase the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load. When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the normally closed switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling. When pump pressure drops to approximately 1379 kPa (200 psi), the switch circuit will re-close and engine idle speed will return to its previous setting. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2797 Power Steering Pressure Switch: Service and Repair REMOVAL The power steering pressure switch is installed in the power steering high-pressure hose. 1. Disconnect electrical connector from power steering pressure switch. 2. Place a small container or shop towel beneath switch to collect any excess fluid. 3. Remove switch. Use back-up wrench on power steering line to prevent line bending. INSTALLATION This switch is used only with 4.7L V-8 engine. 1. Install power steering switch into power steering line. 2. Tighten to 14-22 Nm (124-195 inch lbs.) torque. 3. Connect electrical connector to switch. 4. Check power steering fluid and add as necessary. 5. Start engine and again check power steering fluid. Add fluid if necessary. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Mounting Screws ............................................................................................................................................... 7 Nm (60 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2801 Throttle Position Sensor: Locations The TPS is located on the throttle body. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2802 Throttle Position Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2803 Throttle Position Sensor: Description and Operation The 3-wire Throttle Position Sensor (TPS) is mounted on the throttle body and is connected to the throttle blade. The TPS is a 3-wire variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance (output voltage) of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from 0.26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: - Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - OFF-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2804 Throttle Position Sensor: Service and Repair REMOVAL The TPS is located on the throttle body. 1. Remove air duct and air resonator box at throttle body. Fig. 35 Throttle Body, Sensor And Electrical Connectors 2. Disconnect TPS electrical connector. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2805 Fig. 41 TPS Mounting Bolts 3. Remove two TPS mounting bolts (screws). 4. Remove TPS from throttle body. Fig. 43 TPS Installation Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2806 INSTALLATION The throttle shaft end of throttle body slides into a socket in TPS. The TPS must be installed so that it can be rotated a few degrees. If sensor will not rotate, install sensor with throttle shaft on other side of socket tangs. The TPS will be under slight tension when rotated. 1. Install TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 In. lbs.) torque. 3. Manually operate throttle control lever by hand to check for any binding of TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct/air box to throttle body. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Transmission Position Switch/Sensor: Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2810 Transmission Position Switch/Sensor: Description and Operation DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has six switch contacts that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. - Supply ground to the TCM for backup lamp control in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2816 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2817 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2818 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2819 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2820 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2821 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2822 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2823 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2824 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2825 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2826 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2827 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2828 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2829 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2830 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2831 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2832 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 2833 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Mounting Screws ............................................................................................................................................... 7 Nm (60 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2837 Throttle Position Sensor: Locations The TPS is located on the throttle body. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2838 Throttle Position Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2839 Throttle Position Sensor: Description and Operation The 3-wire Throttle Position Sensor (TPS) is mounted on the throttle body and is connected to the throttle blade. The TPS is a 3-wire variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance (output voltage) of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from 0.26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: - Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - OFF-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2840 Throttle Position Sensor: Service and Repair REMOVAL The TPS is located on the throttle body. 1. Remove air duct and air resonator box at throttle body. Fig. 35 Throttle Body, Sensor And Electrical Connectors 2. Disconnect TPS electrical connector. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2841 Fig. 41 TPS Mounting Bolts 3. Remove two TPS mounting bolts (screws). 4. Remove TPS from throttle body. Fig. 43 TPS Installation Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2842 INSTALLATION The throttle shaft end of throttle body slides into a socket in TPS. The TPS must be installed so that it can be rotated a few degrees. If sensor will not rotate, install sensor with throttle shaft on other side of socket tangs. The TPS will be under slight tension when rotated. 1. Install TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 In. lbs.) torque. 3. Manually operate throttle control lever by hand to check for any binding of TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct/air box to throttle body. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2846 Transmission Position Switch/Sensor: Description and Operation DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has six switch contacts that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. - Supply ground to the TCM for backup lamp control in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2852 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2853 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2854 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2855 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2856 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2857 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2858 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2859 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2860 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2861 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2862 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2863 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2864 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2865 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2866 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2867 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2868 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2869 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation Catalytic Converter: Description and Operation DESCRIPTION California emissions vehicles incorporate mini catalytic converters into the exhaust system. These catalytic converters are made of stainless steel designed to operate at extremely high temperatures. OPERATION The catalytic converter captures and bums any unburned fuel mixture exiting the combustion chambers during the exhaust stroke of the engine. This process aids in reducing emissions output. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 2874 Catalytic Converter: Service and Repair REMOVAL The mini catalytic converters used on the 4.7L engine is an integral part of the exhaust pipe. To replace the mini catalytic converters, the entire exhaust pipe assembly must be replaced. CAUTION: When servicing or replacing exhaust system components, disconnect the oxygen sensor connector(s). Allowing the exhaust to hang by the oxygen sensor wires will damage the harness and/or sensor. 1. Raise and support the vehicle. 2. Saturate the bolts and nuts with Mopar Rust Penetrant. Allow 5 minutes for penetration. 3. Remove the clamp holding the catalytic converter flange to the exhaust pipe(s). 4. Remove the clamp holding the catalytic converter flange to the muffler or extension pipe . 5. Remove the engine rear mount. 6. Remove the crossmember. 7. Remove the catalytic converter. You may have to loosen up other sections of the exhaust system. INSPECTION Look at the stainless steel body of the converter, inspect for bulging or other distortion that could be a result of overheating. If the converter has a heat shield attached make sure it is not bent or loose. If you suspect internal damage to the catalyst, tapping the bottom of the catalyst with a rubber mallet may indicate a damaged core. INSTALLATION CAUTION: When servicing or replacing exhaust system components, disconnect the oxygen sensor connector(s). Allowing the exhaust to hang by the oxygen sensor wires will damage the harness and/or sensor. 1. Align and connect the catalytic converter flange to the exhaust pipe. 2. Install the catalytic converter flange into the muffler or extension pipe. 3. If other sections of the exhaust system where loosened in removal, refer to tightening procedures. 4. At the catalytic converter flange connections, install the clamp and nuts. Tighten the clamp nuts to 41 Nm (30 ft. lbs.) torque. 5. Install the crossmember. 6. Install the rear engine mount. 7. Lower the vehicle. 8. Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels. Adjust the alignment, if needed. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications Canister Purge Solenoid: Specifications EVAP Canister Purge Solenoid Mounting Bolt ...................................................................................................................................... 11 Nm (95 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications > Page 2879 Canister Purge Solenoid: Locations The duty cycle EVAP canister purge solenoid is located at left-rear side of engine compartment near power brake vacuum unit. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications > Page 2880 Duty Cycle EVAP/Purge Solenoid Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications > Page 2881 Canister Purge Solenoid: Description and Operation The duty cycle EVAP canister purge solenoid (DCP) regulates the rate of vapor flow from the EVAP canister to the intake manifold. The Powertrain Control Module (PCM) operates the solenoid. 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 de-energizes 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 cycles (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 that the solenoid is energized. The PCM adjusts solenoid pulse width based on engine operating condition. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications > Page 2882 Canister Purge Solenoid: Service and Repair Fig. 1 Duty Cycle EVAP Canister Purge Solenoid REMOVAL The duty cycle EVAP canister purge solenoid is located at left-rear side of engine compartment near power brake vacuum unit. 1. Disconnect electrical wiring connector at solenoid 2. Disconnect vacuum harness at solenoid. 3. Remove 2 support bracket mounting nuts. 4. Remove solenoid and its support bracket from vehicle. INSTALLATION The duty cycle EVAP canister purge solenoid is located at left-rear side of engine compartment near power brake vacuum unit. 1. Position EVAP canister purge solenoid and its mounting bracket. 2. Install mounting nuts and tighten to 8 Nm (75 In. lbs.) torque. 3. Connect vacuum harness and wiring connector. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications Evaporative Emission Control Canister: Specifications EVAP Canister Mounting Nut .................................................................................................................................................. 17-24 Nm (150-210 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 2886 Evaporative Emission Control Canister: Locations Fig. 22 EVAP Canister Location The EVAP canister is located under the vehicle, inside the left frame rail, in front of the fuel tank. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 2887 Evaporative Emission Control Canister: Description and Operation Fig. 22 EVAP Canister Location A maintenance free, EVAP canister is used on all vehicles. The EVAP canister is located under the vehicle, inside the left frame rail, in front of the fuel tank. The EVAP canister is filled with granules of an activated carbon mixture. Fuel vapors entering the EVAP canister are absorbed by the charcoal granules. Fuel tank pressure vents into the EVAP canister. Fuel vapors are temporarily held in the canister until they can be drawn into the intake manifold. The duty cycle EVAP canister purge solenoid allows the EVAP canister to be purged at predetermined times and at certain engine operating conditions. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 2888 Evaporative Emission Control Canister: Service and Repair Fig. 23 EVAP Canister Location REMOVAL The EVAP canister is located below the vehicle, inside the left frame rail, in front of the fuel tank. 1. Raise vehicle. 2. Disconnect vacuum lines at EVAP canister. Note location of lines before removal. 3. Remove canister mounting nut. 4. Remove canister from mounting bracket. INSTALLATION The EVAP canister is located below the vehicle, inside the left frame rail, in front of the fuel tank. 1. Position canister locating pins into mounting bracket grommets and install mounting nut. 2. Tighten mounting nut to 17-24 Nm (150 - 210 In. lbs.) torque. 3. Connect vacuum lines at canister. 4. Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Specifications Leak Detection Pump: Specifications Leak Detection Pump (LDP) Mounting Screws ........................................................................................................................................ 1 Nm (11 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Specifications > Page 2892 Leak Detection Pump: Locations Fig. 3 Leak Detection Pump (LDP) Location Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Specifications > Page 2893 Fig. 4 LDP Filter Location The LDP is located in the engine compartment under the battery tray and Power Distribution Center (PDC). The LDP filter is attached to the outside of battery tray. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Specifications > Page 2894 Leak Detection Pump Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Specifications > Page 2895 Leak Detection Pump: Description and Operation Leak Detection Pump (LDP) Operation And Diagnosis This bulletin describes the theory of operation for the leak detection system. In addition, information is provided for each of the Diagnostic Trouble Codes (DTC's) as follows: P0442-EVAP LEAK MONITOR 0.040" LEAK DETECTED P0455-EVAP LEAK MONITOR LARGE LEAK DETECTED P0456-EVAP LEAK MONITOR 0.020" LEAK DETECTED P1486-EVAP LEAK MONITOR PINCHED HOSE FOUND P1494-LEAK DETECTION PUMP SW OR MECHANICAL FAULT P1495-LEAK DETECTION PUMP SOLENOID CIRCUIT INTRODUCTION The evaporative emission system is designed to prevent the escape of fuel vapors from the fuel system. Leaks in the system, even small ones, can allow fuel vapors to escape into the atmosphere. Government regulations require on-board testing to make sure that the evaporative (EVAP) system is functioning properly. The leak detection system tests for EVAP system leaks and blockage. It also performs self-diagnostics. During self-diagnostics, the Powertrain Control Module (PCM) first checks the Leak Detection Pump (LDP) for electrical and mechanical faults. If the first checks pass, the PCM then uses the LDP to seal the vent valve and pump air into the system to pressurize it. If a leak is present, the PCM will continue pumping the LDP to replace the air that leaks out. The PCM determines the size of the leak based on how fast/long it must pump the LDP as it tries to maintain pressure in the system. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Specifications > Page 2896 EVAP LEAK DETECTION SYSTEM COMPONENTS Service Port: Used with special tools like the Miller Evaporative Emissions Leak Detector (EELD) to test for leaks in the system. EVAP Purge Solenoid: The PCM uses the EVAP purge solenoid to control purging of excess fuel vapors stored in the EVAP canister. It remains closed during leak testing to prevent loss of pressure. EVAP Canister The EVAP canister stores fuel vapors from the fuel tank for purging. EVAP Purge Orifice: Limits purge volume. EVAP System Air Filter: Provides air to the LDP for pressurizing the system. It filters out dirt while allowing a vent to atmosphere for the EVAP system. Leak Detection Pump (LDP) Components The main purpose of the LDP is to pressurize the fuel system for leak checking. It closes the EVAP system vent to atmospheric pressure so the system can be pressurized for leak testing. The diaphragm is powered by engine vacuum. It pumps air into the EVAP system to develop a pressure of about 7.5' H20(1/4) psi. A reed switch in the LDP allows the PCM to monitor the position of the LDP diaphragm. The PCM uses the reed switch input to monitor how fast the LDP is pumping air into the EVAP system. This allows detection of leaks and blockage. The LDP assembly consists of several parts. The solenoid is controlled by the PCM, and it connects the upper pump cavity to either engine vacuum or atmospheric pressure. A vent valve closes the EVAP system to atmosphere, sealing the system during leak testing. The pump section of the LDP consists of a diaphragm that moves up and down to bring air in through the air filter and inlet check valve, and pump it out through an outlet check valve into the EVAP system. The diaphragm is pulled up by engine vacuum, and pushed down by spring pressure, as the LDP solenoid turns on and off. The LDP also has a magnetic reed switch to signal diaphragm position to the PCM. When the diaphragm is down, the switch is closed, which sends a 12 V (system voltage) signal to the PCM. When the diaphragm is up, the switch is open, and there is no voltage sent to the PCM. This allows the PCM to monitor LDP pumping action as it turns the LDP solenoid on and off. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Specifications > Page 2897 LDP AT REST (NOT POWERED) When the LDP is at rest (no electrical/vacuum) the diaphragm is allowed to drop down if the internal (EVAP system) pressure is not greater than the return spring. The LDP solenoid blocks the engine vacuum port and opens the atmospheric pressure port connected through the EVAP system air filter. The vent valve is held open by the diaphragm. This allows the canister to see atmospheric pressure. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Specifications > Page 2898 DIAPHRAGM UPWARD MOVEMENT When the PCM energizes the LDP solenoid, the solenoid blocks the atmospheric port leading through the EVAP air filter and at the same time opens the engine vacuum port to the pump cavity above the diaphragm. The diaphragm moves upward when vacuum above the diaphragm exceeds spring force. This upward movement closes the vent valve. It also causes low pressure below the diaphragm, unseating the inlet check valve and allowing air in from the EVAP air filter. When the diaphragm completes its upward movement, the LDP reed switch turns from closed to open. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Specifications > Page 2899 DIAPHRAGM DOWNWARD MOVEMENT based on reed switch input, the PCM de-energizes the LDP solenoid, causing it to block the vacuum port, and open the atmospheric port. This connects the upper pump cavity to atmosphere through the EVAP air filter. The spring is now able to push the diaphragm down. The downward movement of the diaphragm closes the inlet check valve and opens the outlet check valve pumping air into the evaporative system. The LDP reed switch turns from open to closed, allowing the PGM to monitor LDP pumping (diaphragm up/down) activity. During the pumping mode, the diaphragm will not move down far enough to open the vent valve The pumping cycle is repeated as the solenoid is turned on and off. When the evaporative system begins to pressurize, the pressure on the bottom of the diaphragm will begin to oppose the spring pressure, slowing the pumping action. The PCM watches the time from when the solenoid is de-energized, until the diaphragm drops down far enough for the reed switch to change from opened to closed. If the reed switch changes too quickly, a leak may be indicated. The longer it takes the reed switch to change state, the tighter the evaporative system is sealed. If the system pressurizes too quickly, a restriction somewhere in the EVAP system may be indicated. PUMPING ACTION During portions of this test, the PCM uses the reed switch to monitor diaphragm movement. The solenoid is only turned on by the PCM after the reed switch changes from open to closed, indicating that the diaphragm has moved down. At other times during the test, the PCM will rapidly cycle the LDP solenoid on and off to quickly pressurize the system. During rapid cycling, the diaphragm will not move enough to change the reed switch state. In the state of rapid cycling, the PCM will use a fixed time interval to cycle the solenoid. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Specifications > Page 2900 Leak Detection Pump: Testing and Inspection ENABLING CONDITIONS TO RUN EVAP LEAK DETECTION TEST NOTE: The following values are approximate and vehicle specific. Use the values seen in pre test/monitor test screen on the DRB III. See TSB 25-02-98 for more detail 1. Cold start: with ambient temperature (obtained from modeling the inlet air temperature sensor on passenger vehicles and the battery temperature sensor on Jeep & truck vehicles) between 4C° (40° F) and 32° C (90° F) for 0.040 leak. Between 4C° (40° F) and 29° C (85° F) for 0.020 leak. 2. Engine coolant temperature within:-12° to -8°C (10° to 18°F) of battery/ambient. 3. Battery voltage between 10 and 15 volts. NOTE: If battery voltage drops below 10 volts for more than 5 seconds during engine cranking, the EVAP leak detection test will not run. 4. Low fuel warning light off (fuel level must be between 15% and 85% for 0.040 leak and 30% and 85% for 0.020 leak). 5. MAP sensor reading 22 in Hg or above (This is the manifold absolute pressure, not vacuum). 6. No engine stall during test. If the system does not pass the EVAP Leak Detection Test, the following DTCs may be set: - P0442 - EVAP LEAK MONITOR 0.040" LEAK DETECTED - P0455 - EVAP LEAK MONITOR LARGE LEAK DETECTED - P0456 - EVAP LEAK MONITOR 0.020" LEAK DETECTED - P1486 - EVAP LEAK MON PINCHED HOSE FOUND - P1494 - LEAK DETECTION PUMP SW OR MECH FAULT - P1495 - LEAK DETECTION PUMP SOLENOID CIRCUIT A DTC will not be set if a one-trip fault is set or if MIL is illuminated for any of the following: - Purge Solenoid Electrical Fault - All Engine Controller Self Test Faults - All Cam And/or Crank Sensor Fault - All Map Sensor Faults - Ambient/battery Temperature Sensor Electrical Faults - All Coolant Sensor Faults - All TPS Faults - LDP Pressure Switch Fault - EGR Solenoid Fault - All Injector Faults - Baro Our Of Range - Vehicle Speed Faults - LDP Solenoid Circuit Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Specifications > Page 2901 Figure 6 EVAP leak detection test sequence When the ignition key is turned to "ON" the LDP diaphragm should be in the down position and the LDP reed switch should be closed. If the EVAP system has residual pressure, the LDP diaphragm may be up. This could result in the LDP reed switch being open when the key is turned to "ON" and a P1494 fault could be set because the PCM is expecting the reed switch to be closed. After the key is turned "ON", the PCM immediately tests the LDP solenoid circuit for electrical faults. If a fault is detected, DTC P1495 will set, the MIL will illuminate, and the remaining EVAP Leak Detection Test is canceled. NOTE: If battery temperature is not within range, or if the engine coolant temperature is not within a specified range of the battery temperature, the PCM will not run tests for DTC P1494, P1486, P0442, P0455 and P0441. These temperature calibrations may be different between models. FIGURE 6 SECTION 2 If DTC P1495 is not set, the PCM will check for DTC P1494. If the LDP reed switch was closed when the key was turned to "ON", the PCM energizes the LDP solenoid for up to 8 seconds and monitors the LDP switch. As the LDP diaphragm is pulled up by engine vacuum, the LDP reed switch should change from closed to open. If it does not, the PCM sets a temporary fault (P1494) in memory, and waits until the next time the Enabling Conditions are met to run the test again. If this is again detected, P1494 is stored and the MIL is illuminated. If the problem is not detected during the next enabling cycle, the temporary fault will be cleared. However, if the PCM detects the reed switch open when the key is turned to "ON", the PCM must determine if this condition is due to residual pressure in the EVAP system, or an actual fault. The PCM stores information in memory on EVAP system purging from previous engine run or drive cycles. If little or no purging took place, residual pressure could be holding the LDP diaphragm up, causing the LDP switch to be open. Since this is not a malfunction, the PCM cancels the EVAP Leak Detection Test without setting the temporary fault. If there was sufficient purging during the previous cycle to eliminate EVAP system pressure, the PCM judges that this is a malfunction and sets a temporary fault in memory. The next time that the Enabling Conditions are met, the test will run again. If the fault is again detected, the MIL will Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Specifications > Page 2902 illuminate and DTC 1494 will be stored. If the fault is not detected, the temporary fault will be cleared. FIGURE 6 SECTION 3 If no fault has been detected so far, the PCM begins testing for possible blockage in the EVAP system between the LDP and the fuel tank. This is done by monitoring the time required for the LDP to pump air into the EVAP system during two to three pump cycles. If no blockage is present, the LDP diaphragm is able to quickly pump air out of the LDP each time the PCM turns oft the LDP solenoid. If a blockage is present, the PCM detects that the LDP takes longer to complete each pump cycle. If the pump cycles take longer than expected (approximately 6 to 10 seconds) the PCM will suspect a blockage. On the next drive when Enabling Conditions are met, the test will run again. If blockage is again detected, P1486 is stored, and the MIL is illuminated. FIGURE 6 SECTION 4 After the LDP blockage tests are completed, the PCM then tests for EVAP system leakage. First, the PCM commands the LDP to rapidly pump for 20 to 50 seconds (depending on fuel level) to build pressure in the EVAP system. This evaluates the system J18-24-0 to see if it can be sufficiently pressurized. This evaluation (rapid pump cycling) may occur several times prior to leak checking. The LDP reed switch does not close and open during rapid pumping because the diaphragm does not travel through its full range during this part of the test. FIGURE 6 SECTION 5 Next, the PCM performs one or more test cycles by monitoring the time required for the LDP reed switch to close (diaphragm to drop) after the LDP solenoid is turned off. If the switch does not close, or closes after a long delay, it means that the system does not have any significant leakage and the EVAP Leak Detection Test is complete. However, if the LDP reed switch closes quickly, there may be a leak or the fuel level may be low enough that the LDP must pump more to finish pressurizing the EVAP system. In this case, the PCM will rapidly pump the LDP again to build pressure in the EVAP system, and follow that by monitoring the time needed for several LDP test cycles. This process of rapid pumping followed by several LDP test cycles may repeat several times before the PCM judges that a leak is present. When leaks are present, the LDP test cycle time will be inversely proportional to the size of the leak. The larger the leak, the shorter the test cycle time. The smaller the leak, the longer the test cycle time. DTC's may be set when a leak as small as 0.5 mm (0.020") diameter is present. If the system detects a leak, a temporary fault will be stored in PCM memory. The time it takes to detect a .020, .040, or Large leak is based on calibrations that vary from model to model. The important point to remember is if a leak is again detected on the next EVAP Leak Detection Test, the MIL will illuminate and a DTC will be stored based on the size of leak detected. If no leak is detected during the next test, the temporary fault will be cleared. DIAGNOSTIC TIPS During diagnosis, you can compare the LDP solenoid activity with the monitor sequence in Figure 6. If the PCM detects a problem that could set a DTC, the testing is halted and LDP solenoid activity will stop. As each section of the test begins, it indicates that the previous section passed successfully. By watching to see which tests complete, you can see if any conditions are present that the PCM considers abnormal. For example, if the LDP solenoid is energized for the test cycles to test for blockage (P1486), it means that the LDP has already passed its test for P1494. Then, if the PCM detects a possible blockage, it will set a temporary fault without turning on the MIL and continue the leak portion of the test. However, the PCM will assume that the system is already pressurized and skip the rapid pump cycles. Always diagnose leaks, if possible, before disconnecting connections. Disconnecting connections may mask a leak condition. Keep in mind that if the purge solenoid seat is leaking, it could go undetected since the leak would end up in the intake manifold. Disconnect the purge solenoid at the manifold when leak checking. In addition, a pinched hose fault (P1486) could set if the purge solenoid does not purge the fuel system properly (blocked seat). The purge solenoid must vent the fuel system prior to the LDP system test. If the purge solenoid cannot properly vent the system the LDP cannot properly complete the test for P1486 and this fault can set due to pressure being in the EVAP system during the test sequence. Multiple actuation's of the DRB Ill® Leak Detection Pump (LDP) Monitor Test can hide a 0.020 leak because of excess vapor generation. Additionally, any source for additional vapor generation can hide a small leak in the EVAP system. Excess vapor generation can delay the fall of the LDP diaphragm thus hiding the small leak. An example of this condition could be bringing a cold vehicle into a warm shop for testing or high ambient temperatures. Fully plugged and partially plugged underhood vacuum lines have been known to set MIL conditions. P1494 and P0456 can be set for this reason. Always, thoroughly, check plumbing for pinches or blockage before condemning components. TEST EQUIPMENT The Evaporative Emission Leak Detector (EELD) Miller Special Tool 8404 is capable of visually detecting leaks in the evaporative system and will take Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Specifications > Page 2903 the place of the ultrasonic leak detector 6917A. The EELD utilizes shop air and a smoke generator to visually detect leaks down to 0.020 or smaller. The food grade oil used to make the smoke includes an UV trace dye that will leave telltale signs of the leak under a black light. This is helpful when components have to be removed to determine the exact leak location. For detailed test instructions, follow the operators manual packaged with the EELD. IMPORTANT Be sure that the PCM has the latest software update. Reprogram as indicated by any applicable Technical Service Bulletin. After LDP repairs are completed, verify the repair by running the DRB Ill® Leak Detection Pump (LDP) Monitor Test as described in Technical Service Bulletin 18-12-99. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Specifications > Page 2904 Leak Detection Pump: Service and Repair REMOVAL Fig. 3 Leak Detection Pump (LDP) Location Fig. 4 LDP Filter Location The LDP is located in the engine compartment under the battery tray and Power Distribution Center (PDC). The LDP filter is attached to the outside of battery tray. The LDP and LDP filter are replaced (serviced) as one unit. 1. Disconnect negative battery cable at battery. 2. Remove battery. 3. Carefully disconnect rubber hose from bottom of LDP filter. 4. Remove clip retaining LDP filter to battery tray and remove filter from tray. 5. Disconnect battery temperature sensor pigtail wiring harness at bottom of battery tray. 6. To gain access to LDP, the PDC must be partially removed. Remove PDC-to-fender mounting screw at rear of PDC. Unsnap PDC from battery tray. To prevent damage to PDC wiring, carefully position PDC to gain access to LDP. 7. Remove battery tray. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Specifications > Page 2905 8. Carefully remove vapor/vacuum lines at LDP. 9. Disconnect electrical connector at LDP. Fig. 5 Leak Detection Pump (LDP) Mounting Screws 10. Remove 3 LDP mounting screws and remove LDP from vehicle. INSTALLATION The LDP is located in the engine compartment under the battery tray and Power Distribution Center (PDC). The LDP filter is attached to the outside of battery tray. The LDP and LDP filter are replaced (serviced) as one unit. 1. Install LDP to bottom of battery tray. Tighten screws to 1 Nm (11 In. lbs.) torque. 2. Carefully install vapor/vacuum lines to LDP. The vapor/vacuum lines and hoses must be firmly connected. Check the vapor/vacuum lines at the LDP, LDP filter and EVAP canister purge solenoid for damage or leaks. If a leak is present, a Diagnostic Trouble Code (DTC) may be set. 3. Connect electrical connector to LDP. 4. Install battery tray. 5. Install PDC to fender and battery tray (snaps on to battery tray). 6. Install LDP filter to battery tray (one clip). 7. Install connecting hose to bottom of LDP filter. 8. Connect battery temperature sensor pigtail wiring harness. 9. Install battery. 10. Connect negative battery cable to battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Vacuum Line > Component Information > Testing and Inspection EGR Vacuum Line: Testing and Inspection A vacuum line schematic for emission related items can be found on the Vehicle Emission Control Information (VECI) label. For label location, refer to Vehicle Emission Control Information (VECI) Label. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations Positive Crankcase Ventilation Valve: Locations Fig. 20 PCV Valve/Oil Filler Tube Location The PCV valve is located on the oil filler tube Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 2914 Positive Crankcase Ventilation Valve: Description and Operation This engine is equipped with a closed crankcase ventilation system and a Positive Crankcase Ventilation (PCV) valve. This system consists of: Fig. 7 PCV Valve/Oil Filler Tube (Housing) - a PCV valve mounted to the oil filler housing. The PCV valve is sealed to the oil filler housing with an O-ring. - the air cleaner housing Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 2915 Fig. 8 PCV System Hoses/Tubes - two interconnected breathers threaded into the rear of each cylinder head. - tubes and hose to connect the system components. The PCV system operates by engine intake manifold vacuum. Filtered air is routed into the crankcase through the air cleaner hose and crankcase breathers. The metered air, along with crankcase vapors, are drawn through the PCV valve and into a passage in the intake manifold. The PCV system manages crankcase pressure and meters blow-by gases to the intake system, reducing engine sludge formation. The PCV valve contains a spring loaded plunger. This plunger meters the amount of crankcase vapors routed into the combustion chamber based on intake manifold vacuum. Fig. 13 Engine Off Or Engine Pop-Back - No Vapor Flow Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 2916 Fig. 14 High Intake Manifold Vacuum - Minimal Vapor Flow Fig. 15 Moderate Intake Manifold Vacuum - Maximum Vapor Flow TYPICAL PCV valves are shown in, and. When the engine is not operating, or during an engine pop-back, the spring forces the plunger back against the seat. This will prevent vapors from flowing through the valve. During periods of high manifold vacuum, such as idle or cruising speeds, vacuum is sufficient to completely compress spring. It will then pull the plunger to the top of the valve. In this position there is minimal vapor flow through the valve. During periods of moderate manifold vacuum, the plunger is only pulled part way back from inlet. This results in maximum vapor flow through the valve. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 2917 Positive Crankcase Ventilation Valve: Testing and Inspection Fig. 19 PCV Valve/Oil Filler Tube 1. Disconnect PCV line/hose by disconnecting rubber connecting hose at PCV valve fitting. 2. Remove PCV valve at oil filler tube by rotating PCV valve downward until locating tabs have been freed at cam lock. After tabs have cleared, pull valve straight out from filler tube. To prevent damage to PCV valve locating tabs, valve must be pointed downward for removal. Do not force valve from oil filler tube. 3. After valve is removed, check condition of valve O-ring. Also, PCV valve should rattle when shaken. 4. Reconnect PCV valve to its connecting line/hose. 5. Start engine and bring to idle speed. 6. If valve is not plugged, a hissing noise will be heard as air passes through valve. Also, a strong vacuum should be felt with a finger placed at valve inlet. 7. If vacuum is not felt at valve inlet, check line/ hose for kinks or for obstruction. If necessary, clean out intake manifold fitting at rear of manifold. Do this by turning a 1/4 inch drill (by hand) through the fitting to dislodge any solid particles. Blow out the fitting with shop air. If necessary, use a smaller drill to avoid removing any metal from the fitting. 8. Do not attempt to clean the old PCV valve. 9. Return PCV valve back to oil filler tube by placing valve locating tabs into cam lock. Press PCV valve in and rotate valve upward. A slight click will be felt when tabs have engaged cam lock. Valve should be pointed towards rear of vehicle. 10. Connect PCV line/hose and connecting rubber hose to PCV valve. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 2918 Fig. 20 PCV Breathers/Tubes/Hoses 11. Disconnect rubber hose from fresh air fitting at left side of air cleaner resonator box. Start engine and bring to idle speed. Hold a piece of stiff paper (such as a parts tag) loosely over the opening of the disconnected rubber hose. 12. The paper should be drawn against the hose opening with noticeable force. This will be after allowing approximately one minute for crankcase pressure to reduce. 13. If vacuum is not present, disconnect each PCV system hose at top of each breather. Check for obstructions or restrictions. 14. If vacuum is still not present, remove each PCV system breather from each cylinder head. Check for obstructions or restrictions. If plugged, replace breather. Tighten breather to 12 Nm (106 In. lbs.) torque. Do not attempt to clean breather 15. If vacuum is still not present, disconnect each PCV system hose at each fitting and check for obstructions or restrictions. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 2919 Positive Crankcase Ventilation Valve: Service and Repair Fig. 21 PCV Valve/Oil Filler Tube Location REMOVAL The PCV valve is located on the oil filler tube. Two locating tabs are located on the side of the valve. These 2 tabs fit into a cam lock in the oil filler tube. An O-ring seals the valve to the filler tube. 1. Disconnect PCV line/hose by disconnecting rubber hose at PCV valve fitting. 2. Remove PCV valve at oil filler tube by rotating PCV valve downward (counter-clockwise) until locating tabs have been freed at cam lock. After tabs have cleared, pull valve straight out from filler tube. To prevent damage to PCV valve locating tabs, valve must be pointed downward for removal. Do not force valve from oil filler tube. 3. After valve is removed, check condition of valve O-ring. INSTALLATION The PCV valve is located on the oil filler tube. Two locating tabs are located on the side of the valve. These 2 tabs fit into a cam lock in the oil filler tube. An O-ring seals the valve to the filler tube. 1. Return PCV valve back to oil filler tube by placing valve locating tabs into cam lock. Press PCV valve in and rotate valve upward. A slight click will be felt when tabs have engaged cam lock. Valve should be pointed towards rear of vehicle. 2. Connect PCV line/hose and rubber hose to PCV valve. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions 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 °C (1000 °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. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions > Page 2928 Fuel Pressure Release: Service and Repair Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator Clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications Accelerator Pedal: Specifications Accelerator Pedal Bracket Mounting Nuts ................................................................................................................................................ 7 Nm (65 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 2935 Accelerator Pedal: Service and Repair REMOVAL All engines are equipped with torsion return springs located on the throttle body shaft. These engines equipped with a manual transmission have an additional pedal return spring on the throttle body linkage. CAUTION: Be careful not to damage or kink the cable core wire (within the cable sheathing) while servicing accelerator pedal or cables. Fig. 13 Accelerator Pedal - Removal Or Installation 1. From inside the vehicle, hold up accelerator pedal. Remove plastic cable retainer and throttle cable core wire from upper end of pedal arm (Fig. 13). Plastic cable retainer snaps into pedal arm. 2. Remove two accelerator pedal/bracket nuts (Fig. 13)and remove pedal/bracket assembly from vehicle. INSTALLATION All engines are equipped with torsion return springs located on the throttle body shaft. These engines equipped with a manual transmission have an additional pedal return spring on the throttle body linkage. 1. Position pedal/bracket assembly over the two dash panel mounting studs and install retaining nuts. 2. Tighten nuts to 7 Nm (65 In. lbs.) torque. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 2936 Fig. 14 Index Tab And Slot 3. From inside the vehicle, hold up the accelerator pedal. Install the throttle cable core wire and plastic cable retainer into 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 (Fig. 14). Align the index slot (Fig. 14) on the plastic cable retainer to this index tab. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL Housing removal is not necessary for element (filter) replacement. 1. Pry up spring clips from housing cover (spring clips retain cover to housing). 2. Release housing cover from locating tabs on housing (Fig. 11) and remove cover. 3. Remove air cleaner element (filter) from housing. 4. Clean inside of housing before replacing element. INSTALLATION 1. Install element into housing. 2. Position housing cover into housing locating tabs. 3. Pry up spring clips and lock cover to housing. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Service Precautions Fuel: Service Precautions CAUTION: Your vehicle must use unleaded fuel only. Using leaded fuel will damage the catalytic converter and affect the warranty coverage validity. CAUTION: DO NOT use gasoline containing methanol. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Locations Fuel Filler Cap: Locations The plastic fuel tank filler tube cap is threaded onto the end of the fuel fill tube. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Locations > Page 2947 Fuel Filler Cap: Description and Operation The plastic fuel tank filler tube cap is threaded onto the end of the fuel fill tube. Certain models are equipped with a 1/4 turn cap. The loss of any fuel or vapor out of fuel filler tube is prevented by the use of a pressure-vacuum fuel fill cap. Relief valves inside the cap will release fuel tank pressure at predetermined pressures. Fuel tank vacuum will also be released at predetermined values. This cap must be replaced by a similar unit if replacement is necessary. This is in order for the system to remain effective. CAUTION: Remove fill cap before servicing any fuel system component to relieve tank pressure. If equipped with a California emissions package and a Leak Detection Pump (LDP), the cap must be tightened securely. If cap is left loose, a Diagnostic Trouble Code (DTC) may be set. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Locations > Page 2948 Fuel Filler Cap: Service and Repair REMOVAL/INSTALLATION If replacement of the 1/4 turn fuel tank filler tube cap is necessary, it must be replaced with an identical cap to be sure of correct system operation. CAUTION: Remove the fuel tank filler tube cap to relieve fuel tank pressure. The cap must be removed prior to disconnecting any fuel system component or before draining the fuel tank. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions 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 °C (1000 °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. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2953 Fuel Pressure Release: Service and Repair Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator Clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Hose Clamp > Component Information > Specifications Fuel Hose Clamp: Specifications Fuel Hose Clamps ............................................................................................................................... ...................................................... 3 Nm (25 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications Fuel Injector: Specifications Resistance 12.0 ohms +/- 1.2 ohms At 20 degrees C (68 degrees F) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2960 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2961 Fuel Injector: Diagrams Fuel Injector No.1 Fuel Injector No.2 Fuel Injector No.3 Fuel Injector No.4 Fuel Injector No.5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2962 Fuel Injector No.6 Fuel Injector No.7 Fuel Injector No.8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2963 Fuel Injector: Service Precautions WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE EVEN WITH ENGINE TURNED OFF. BEFORE SERVICING FUEL INJECTOR(S), FUEL SYSTEM PRESSURE MUST BE RELEASED. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2964 Fuel Injector: Description and Operation Fig. 20 Fuel Injector - Typical An individual fuel injector (Fig. 20) is used for each individual cylinder. The top (fuel entry) end of the injector (Fig. 20) is attached into an opening on the fuel rail. The fuel injectors are electrical solenoids. The injector contains a pintle that closes OFF an orifice at the nozzle end. When electric current is supplied to the injector, the armature and needle move a short distance against a spring, allowing fuel to flow out the orifice. Because the fuel is under high pressure, a fine spray is developed in the shape of a pencil stream. The spraying action atomizes the fuel, adding it to the air entering the combustion chamber. The nozzle (outlet) 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. 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. Battery voltage is supplied to the injectors through the ASD relay. The PCM determines injector pulse width based on various inputs. PCM Output 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. 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. Battery voltage (12 volts +) is supplied to the injectors through the ASD relay. The ASD relay will shutdown the 12 volt power source to the fuel injectors if the PCM senses the ignition is ON, but the engine is not running. This occurs after the engine has not been running for approximately 1.8 seconds. The PCM determines injector on-time (pulse width) based on various inputs. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2965 Fuel Injector: Testing and Inspection To perform a complete test of the fuel injectors and their circuitry, use the DRB scan tool and refer to the appropriate Powertrain Diagnostics Procedures. To test the injector only, refer to the following: Disconnect the fuel injector wire harness connector from the injector. The injector is equipped with 2 electrical terminals (pins). Place an ohmmeter across the terminals. Resistance reading should be approximately 12 ohms ± 1.2 ohms at 20 °C (68 °F). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2966 Fuel Injector: Service and Repair REMOVAL WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE EVEN WITH ENGINE TURNED OFF. BEFORE SERVICING FUEL INJECTOR(S), FUEL SYSTEM PRESSURE MUST BE RELEASED. To release fuel pressure, refer to Fuel System Pressure Release Procedure. To remove one or more fuel injectors, fuel rail assembly must be removed from engine. 1. Remove air cleaner assembly. 2. Remove fuel injector rail assembly. Refer to Fuel Injector Rail Removal/Installation. Fig. 22 Mounting Bolts (Screws) - IAC Motor Fig. 23 Intake Manifold Air Temperature Sensor - Typical 3. Remove clip(s) retaining the injector(s) to fuel rail (Fig. 22) or (Fig. 23). 4. Remove injector(s) from fuel rail. INSTALLATION WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE EVEN WITH ENGINE TURNED OFF. BEFORE SERVICING Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2967 FUEL INJECTOR(S), FUEL SYSTEM PRESSURE MUST BE RELEASED. To release fuel pressure, refer to Fuel System Pressure Release Procedure. To remove one or more fuel injectors, fuel rail assembly must be removed from engine. 1. Apply a small amount of clean engine oil to each fuel injector O-ring. This will help in fuel rail installation. 2. Install injector(s) and injector clip(s) to fuel rail. 3. Install fuel rail assembly. Refer to Fuel Injector Rail Removal/Installation. 4. Install air cleaner. 5. Start engine and check for leaks. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Locations Fuel Line Coupler: Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Locations > Page 2971 Fuel Line Coupler: Service Precautions WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSE, FITTING OR LINE, FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO FUEL SYSTEM PRESSURE RELEASE PROCEDURE. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Locations > Page 2972 Fuel Line Coupler: Description and Operation QUICK CONNECT FITTING Different types of quick-connect fittings are used to attach various fuel system components, lines and tubes. These are: a single-tab type, a two-tab type or a plastic retainer ring type. Some are equipped with safety latch clips. Some may require the use of a special tool for disconnection and removal. Refer to Quick-Connect Fittings Removal/Installation for more information. CAUTION: The interior components (O-rings, clips) of quick-connect fittings are not serviced separately, but new plastic spacers are available for some types. If service parts are not available, do not attempt to repair the damaged fitting or fuel line (tube). If repair is necessary, replace the complete fuel line (tube) assembly. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Locations > Page 2973 Fuel Line Coupler: Service and Repair Also refer to Fuel Tubes/Lines/Hoses and Clamps. Different types of quick-connect fittings are used to attach various fuel system components, lines and tubes. These are: a single-tab type, a two-tab type or a plastic retainer ring type. Safety latch clips are used on certain components/lines. Certain fittings may require use of a special tool for disconnection. DISCONNECTING WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSE, FITTING OR LINE, FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO FUEL SYSTEM PRESSURE RELEASE PROCEDURE. CAUTION: The interior components (O-rings, spacers) of some types of quick-connect fitting are not serviced separately. If service parts are not available, do not attempt to repair a damaged fitting or fuel line. If repair is necessary, replace complete fuel line assembly. 1. Perform fuel pressure release procedure. Refer to Fuel Pressure Release Procedure. 2. Disconnect negative battery cable from battery. 3. Clean fitting of any foreign material before disassembly. Fig. 29 Single-Tab Type Fitting 4. Single-Tab Type Fitting: This type of fitting is equipped with a single pull tab (Fig. 29). The tab is removable. After tab is removed, quick-connect fitting can be separated from fuel system component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Locations > Page 2974 Fig. 30 Disconnecting Single-Tab Type Fitting a. Press release tab on side of fitting to release pull tab (Fig. 30). If release tab is not pressed prior to releasing pull tab, pull tab Will be damaged. b. While pressing release tab on side of fitting, use screwdriver to pry up pull tab (Fig. 30). Fig. 31 Removing Pull Tab c. Raise pull tab until it separates from quick-connect fitting (Fig. 31). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Locations > Page 2975 Fig. 32 Typical Two-Tab Type Quick-Connect Fitting 5. Two-Tab Type Fitting: This type of fitting is equipped with tabs located on both sides of fitting (Fig. 32). The tabs are supplied for disconnecting quick-connect fitting from component being serviced. a. To disconnect quick-connect fitting, squeeze plastic retainer tabs (Fig. 32) against sides of quick-connect fitting with your fingers. Tool use is not required for removal and may damage plastic retainer. b. Pull fitting from fuel system component being serviced. c. The plastic retainer will remain on component being serviced after fitting is disconnected. The O-rings and spacer will remain in quick-connect fitting connector body. Fig. 33 Plastic Retainer Ring Type Fitting 6. Plastic Retainer Ring Type Fitting: This type of fitting can be identified by the use of a full-round plastic retainer ring (Fig. 33) usually black in color. a. To release fuel system component from quick-connect fitting, firmly push fitting towards component being serviced while firmly pushing plastic retainer ring into fitting (Fig. 33). With plastic ring depressed, pull fitting from component. The plastic retainer ring must be pressed Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Locations > Page 2976 squarely into fitting body. If this retainer is cocked during removal, it may be difficult to disconnect fitting. Use an open-end wrench on shoulder of plastic retainer ring to aid in disconnection. b. After disconnection, plastic retainer ring will remain with quick-connect fitting connector body. c. Inspect fitting connector body, plastic retainer ring and fuel system component for damage. Replace as necessary. Fig. 34 Latch Clip - Type 1 Fig. 35 Latch Clip - Type 2 7. Latch Clips: Depending on vehicle model and engine, 2 different types of safety latch clips are used (Fig. 34) or (Fig. 35). Type-1 is tethered to fuel line and type-2 is not. A special tool will be necessary to disconnect fuel line after latch clip is removed. The latch clip may be used on certain fuel line/fuel rail connection, or to join fuel lines together. a. Type 1: Pry up on latch clip with a screwdriver (Fig. 34). b. Type 2: Separate and unlatch 2 small arms on end of clip (Fig. 35) and swing away from fuel line. c. Slide latch clip toward fuel rail while lifting with screwdriver. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Locations > Page 2977 Fig. 36 Fuel Line Disconnection Using Special Tool d. Insert special fuel line removal tool (Snap-On number FIH 9055-1 or equivalent) into fuel line (Fig. 36). Use tool to release locking fingers in end of line. e. With special tool still inserted, pull fuel line from fuel rail. f. After disconnection, locking fingers will remain within quick-connect fitting at end of fuel line. 8. Disconnect quick-connect fitting from fuel system component being serviced. CONNECTING 1. Inspect quick-connect fitting body and fuel system component for damage. Replace as necessary. 2. Prior to connecting quick-connect fitting to component being serviced, check condition of fitting and component. Clean parts with a lint-free cloth. Lubricate with clean engine oil. 3. Insert quick-connect fitting into fuel tube or fuel system component until built-on stop on fuel tube or component rests against back of fitting. 4. Continue pushing until a click is felt. 5. Single-tab type fitting: Push new tab down until it locks into place in quick-connect fitting. 6. Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.). 7. Latch Clip Equipped: Install latch clip (snaps into position). If latch clip will not fit, this indicates fuel line is not properly installed to fuel rail (or other fuel line). Recheck fuel line connection. 8. Connect negative cable to battery. 9. Start engine and check for leaks. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations Fuel Pressure Regulator: Locations Fig. 4 Filter/Regulator Location A combination fuel filter and fuel pressure regulator is located on the top of the fuel pump module. A separate frame mounted fuel filter is not used with any engine. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 2981 Fuel Pressure Regulator: Service Precautions WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE, EVEN WITH ENGINE OFF. BEFORE SERVICING THE FUEL FILTER/FUEL PRESSURE REGULATOR, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 2982 Fuel Pressure Regulator: Description and Operation Fig. 2 Side View - Filter/Regulator Fig. 3 Fuel Filter/Fuel Pressure Regulator FUEL FILTER/PRESSURE REGULATOR A combination fuel filter and fuel pressure regulator (Fig. 2) is used on all engines. It is located on the top of the fuel pump module. A separate frame mounted fuel filter is not used with any engine. Both fuel filters (at bottom of fuel pump module and within fuel pressure regulator) are designed for extended service. They do not require normal scheduled maintenance. Filters should only be replaced if a diagnostic procedure indicates to do so. Fuel Pressure Regulator Operation: The pressure regulator is a mechanical device that is not controlled by engine vacuum or the powertrain control module (PCM). 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 (Fig. 2) is also part of the assembly. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 2983 Fuel is supplied to the filter/regulator by the electric fuel pump through an opening tube at the bottom of filter/regulator (Fig. 2). The regulator acts as a check valve to maintain some fuel pressure when the engine is not operating. This will help to start the engine. A second check valve is located at the outlet end of the electric fuel pump. Refer to Fuel Pump Description and Operation for more information. Also refer to the Fuel Pressure Leak Down Test and the Fuel Pump Pressure Tests. If fuel pressure at the pressure regulator exceeds approximately 49.2 psi, an internal diaphragm opens and excess fuel pressure is routed back into the tank through the bottom of pressure regulator. Both fuel filters (at bottom of fuel pump module and within fuel pressure regulator) are designed for extended service. They do not require normal scheduled maintenance. Filters should only be replaced if a diagnostic procedure indicates to do so. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 2984 Fuel Pressure Regulator: Service and Repair REMOVAL WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE, EVEN WITH ENGINE OFF. BEFORE SERVICING THE FUEL FILTER/FUEL PRESSURE REGULATOR, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. Refer to Fuel System Pressure Release in the Fuel Delivery System. Fig. 4 Filter/Regulator Location The fuel filter/fuel pressure regulator is located at top of fuel pump module on top of fuel tank (Fig. 4), Fuel pump module removal is not necessary for filter/regulator removal 1. Drain fuel tank and remove tank. Refer to Fuel Tank Removal/Installation. 2. Clean area around filter/regulator to prevent contaminants from entering pump module. 3. The fuel filter/regulator is pressed into a rubber grommet. Remove by twisting and pulling straight up. CAUTION: Do not pull filter/regulator more than three inches from fuel pump module. Damage to coiled fuel tube (line) may result. Fig. 5 Fuel Tube And Clamp - Typical Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 2985 4. Gently cut old fuel tube (line) clamp (Fig. 5) taking care not to damage plastic fuel tube. Remove and discard old fuel tube clamp. 5. Remove plastic fuel tube from filter/regulator by gently pulling downward. Remove filter/regulator from fuel pump module. INSTALLATION 1. Install a new clamp over plastic fuel tube. Fig. 6 Tightening Fuel Filter Tube Clamp - Typical 2. Install filter/regulator to fuel tube. Rotate filter/regulator in fuel tube (line) (Fig. 6) until it is pointed towards front of tank (or front of vehicle). 3. Tighten line clamp to fuel line using special Hose Clamp Pliers number C-4124 or equivalent (Fig. 6). Do not use conventional side cutters to tighten this type of clamp. 4. Press filter/regulator (by hand) into rubber grommet. 5. Rotate filter/regulator until pointed towards front of vehicle (Fig. 4). 6. Install fuel tank. Refer to Fuel Tank Removal/Installation. 7. Check for fuel leaks. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Power Distribution Center Fuel Pump Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 2997 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 2998 Fuel Pump Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 2999 Fuel Pump Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3000 Fuel Pump Relay: Description and Operation The 5-pin, 12-volt, fuel pump relay is located in the Power Distribution Center (PDC). Refer to the label on the PDC cover for relay location. The Powertrain Control Module (PCM) energizes the electric fuel pump through the fuel pump relay. The fuel pump relay is energized by first applying battery voltage to it when the ignition key is turned ON, and then applying a ground signal to the relay from the PCM. Whenever the ignition key is turned ON, the electric fuel pump will operate. But, the PCM will shutdown the ground circuit to the fuel pump relay in approximately 1-3 seconds unless the engine is operating or the starter motor is engaged. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3001 Fuel Pump Relay: Testing and Inspection Fig. 1 ASD And Fuel Pump Relay Terminals - Type 1 Fig. 2 ASD And Fuel Pump Terminals - Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, (Fig. 1) or (Fig. 2). - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3002 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3003 Fuel Pump Relay: Service and Repair Fig. 21 Power Distribution Center (PDC) REMOVAL The fuel pump relay is located in the Power Distribution Center (PDC) (Fig. 21). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The fuel pump relay is located in the Power Distribution Center (PDC) (Fig. 21). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Locations Fuel Pump Pickup Filter: Locations The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module. The fuel pump module is located inside of fuel tank. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Locations > Page 3007 Fuel Pump Pickup Filter: Service and Repair Fig. 28 Fuel Pump Inlet Filter REMOVAL The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module (Fig. 28). The fuel pump module is located inside of fuel tank. 1. Remove fuel tank. 2. Remove fuel pump module. 3. Remove filter by carefully prying 2 lock tabs at bottom of module with 2 screwdrivers. Filter is snapped to module. 4. Clean bottom of pump module. INSTALLATION The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module (Fig. 28). The fuel pump module is located inside of fuel tank. 1. Snap new filter to bottom of module. Be sure O-ring is in correct position. 2. Install fuel pump module. 3. Install fuel tank. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications Fuel Rail: Specifications Fuel Rail Mounting Bolts ...................................................................................................................... .................................................. 27 Nm (20 Ft. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 3011 Fuel Rail: Locations The fuel injector rail is mounted to the intake manifold. A fuel pressure test port is located on the fuel rail. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 3012 Fuel Rail: Service Precautions WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE TURNED OFF). BEFORE SERVICING FUEL RAIL ASSEMBLY, FUEL SYSTEM PRESSURE MUST BE RELEASED. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 3013 Fuel Rail: Description and Operation Fig. 18 Fuel Injector Rail The fuel injector rail is used to mount the fuel injectors to the engine. It is mounted to the intake manifold (Fig. 18). High pressure fuel from the fuel pump is routed to the fuel rail. The fuel rail then supplies the necessary fuel to each individual fuel injector. A fuel pressure test port is located on the fuel rail (Fig. 18). A quick-connect fitting with a safety latch is used to attach the fuel line to the fuel rail. The fuel rail is not repairable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 3014 Fuel Rail: Service and Repair REMOVAL WARNING: THE FUEL SYSTEM IS UNDER CONSTANT PRESSURE EVEN WITH ENGINE OFF. BEFORE SERVICING FUEL RAIL , FUEL SYSTEM PRESSURE MUST BE RELEASED. Fig. 24 Fuel Rail Mounting CAUTION: The left and right fuel rails are replaced as an assembly. Do not attempt to separate rail halves at connector tube (Fig. 24). Due to design of tube, it does not use any clamps. Never attempt to install a clamping device of any kind to tube. When removing fuel rail assembly for any reason, be careful not to bend or kink tube. 1. Remove fuel tank filler tube cap. 2. Perform Fuel System Pressure Release Procedure. 3. Remove negative battery cable at battery. 4. Remove air duct at throttle body air box. 5. Remove air box at throttle body. 6. Remove wiring at rear of generator. 7. Disconnect fuel line latch clip and fuel line at fuel rail. A special tool will be necessary for fuel line disconnection. Refer to Quick-Connect Fittings. 8. Remove vacuum lines at throttle body. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 3015 Fig. 25 Remove/Install Injector Connector 9. Disconnect electrical connectors at all 8 fuel injectors. To remove connector refer to (Fig. 25). Push red colored slider away from injector (1). While pushing slider, depress tab (2) and remove connector (3) from injector. The factory fuel injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If harness is not tagged, note wiring location before removal. 10. Disconnect electrical connectors at throttle body. 11. Disconnect electrical connectors at MAP and IAT sensors. 12. Remove first three ignition coils on each bank (cylinders # 1, 3, 5, 2, 4 and 6). 13. Remove 4 fuel rail mounting bolts (Fig. 24). 14. Gently rock and pull left side of fuel rail until fuel injectors just start to clear machined holes in cylinder head. Gently rock and pull right side of rail until injectors just start to clear cylinder head holes. Repeat this procedure (left/right) until all injectors have cleared cylinder head holes. 15. Remove fuel rail (with injectors attached) from engine. 16. If fuel injectors are to be removed, refer to Fuel Injector Removal/Installation. INSTALLATION 1. If fuel injectors are to be installed, refer to Fuel Injector Removal/Installation. 2. Apply a small amount of engine oil to each fuel injector O-ring. This will help in fuel rail installation. 3. Position fuel rail/fuel injector assembly to machined injector openings in cylinder head. 4. Guide each injector into cylinder head. Be careful not to tear injector O-rings. 5. Push right side of fuel rail down until fuel injectors have bottomed on cylinder head shoulder. Push left fuel rail down until injectors have bottomed on cylinder head shoulder. 6. Install 4 fuel rail mounting bolts and tighten to 27 Nm (20 ft. lbs.). 7. Install ignition coils. 8. Connect electrical connectors to throttle body. 9. Connect electrical connectors to MAP and IAT sensors. 10. Connect electrical connectors at all fuel injectors. To install connector, refer to (Fig. 25). Push connector onto injector (1) and then push and lock red colored slider (2). Verify connector is locked to injector by lightly tugging on connector. 11. Connect vacuum lines to throttle body. 12. Connect fuel line latch clip and fuel line to fuel rail. Refer to Quick-Connect Fittings. 13. Connect wiring to rear of generator. 14. Install air box to throttle body. 15. Install air duct to air box. 16. Connect battery cable to battery. 17. Start engine and check for leaks. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service Precautions Fuel Return Line: Service Precautions 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service Precautions > Page 3019 Fuel Return Line: Description and Operation FUEL LINES Also refer to Quick-Connect Fittings. 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. The lines/tubes/hoses used on fuel injected vehicles are of a special construction. This is due to the higher fuel pressures and the possibility of contaminated fuel in this system. If it is necessary to replace these lines/tubes/hoses, only those marked EFM/EFI may be used. If equipped: The hose clamps used to secure rubber hoses on fuel injected vehicles are of a special rolled edge construction. This construction is used to prevent the edge of the clamp from cutting into the hose. Only these rolled edge type clamps may be used in this system. All other types of clamps may cut into the hoses and cause high-pressure fuel leaks. Use new original equipment type hose clamps. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service Precautions Fuel Supply Line: Service Precautions 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service Precautions > Page 3023 Fuel Supply Line: Description and Operation FUEL LINES Also refer to Quick-Connect Fittings. 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. The lines/tubes/hoses used on fuel injected vehicles are of a special construction. This is due to the higher fuel pressures and the possibility of contaminated fuel in this system. If it is necessary to replace these lines/tubes/hoses, only those marked EFM/EFI may be used. If equipped: The hose clamps used to secure rubber hoses on fuel injected vehicles are of a special rolled edge construction. This construction is used to prevent the edge of the clamp from cutting into the hose. Only these rolled edge type clamps may be used in this system. All other types of clamps may cut into the hoses and cause high-pressure fuel leaks. Use new original equipment type hose clamps. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations Fuel Gauge Sender: Locations Fig. 7 Fuel Gauge Sending Unit Location - Typical Module The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The fuel pump module is located inside of fuel tank. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 3028 Fuel Gauge Sender: Description and Operation FUEL LEVEL SENDING UNIT / SENSOR The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation: A constant input voltage source of about 12 volts (battery voltage) is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 3029 Fuel Gauge Sender: Testing and Inspection The fuel gauge sending unit contains a variable resistor (track). As the float moves up or down, electrical resistance will change. Refer to Instrument Panel and Gauges for Fuel Gauge testing. To test the gauge sending unit only, it must be removed from vehicle. The unit is part of the fuel pump module. Refer to Fuel Pump Module Removal/installation for procedures. Measure the resistance across the sending unit terminals. With float in up position, resistance should be 20 ohms ± 6%. With float in down position, resistance should be 270 ohms ± 6%. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 3030 Fuel Gauge Sender: Service and Repair REMOVAL Fig. 7 Fuel Gauge Sending Unit Location - Typical Module The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module (Fig. 7). The fuel pump module is located inside of fuel tank. 1. Remove fuel tank. 2. Remove fuel pump module. 3. Unplug 4-way electrical connector (Fig. 7). 4. Disconnect 2 sending unit wires at 4-way connector. The locking collar of connector must be removed before wires can be released from connector. Note location of wires within 4-way connector. Fig. 8 Fuel Gauge Sending Unit Lock Tab/Tracks Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 3031 5. The sending unit is retained to pump module with a small lock tab and notch (Fig. 8). Carefully push lock tab to the side and away from notch while sliding sending unit downward on tracks for removal. Note wire routing while removing unit from module. INSTALLATION The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module (Fig. 7). The fuel pump module is located inside of fuel tank. 1. Position sending unit into tracks. Note wire routing. 2. Push unit on tracks until lock tab snaps into notch. 3. Connect 2 sending unit wires into 4-way connector and install locking collar. 4. Connect 4-way electrical connector to module. 5. Install fuel pump module. 6. Install fuel tank. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications Idle Air Control (IAC) Motor: Specifications IAC Motor-To-Throttle Body Bolts .......................................................................................................................................................... 7 Nm (60 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 3035 Idle Air Control (IAC) Motor: Locations The IAC motor is located on the throttle body. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 3036 Idle Air Control Motor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 3037 Idle Air Control (IAC) Motor: Description and Operation The IAC stepper motor is mounted to the throttle body, and regulates the amount of air bypassing the control of the throttle plate. As engine loads and ambient temperatures change, engine rpm changes. A pintle on the IAC stepper motor protrudes into a passage in the throttle body, controlling air flow through the passage. The IAC is controlled by the Powertrain Control Module (PCM) to maintain the target engine idle speed. At idle, engine speed can be increased by retracting the IAC motor pintle and allowing more air to pass through the port, or it can be decreased by restricting the passage with the pintle and diminishing the amount of air bypassing the throttle plate. The IAC is called a stepper motor because it is moved (rotated) in steps, or increments. Opening the IAC opens an air passage around the throttle blade which increases RPM. The PCM uses the IAC motor to control idle speed (along with timing) and to reach a desired MAP during decel (keep engine from stalling). The IAC motor has 4 wires with 4 circuits. Two of the wires are for 12 volts and ground to supply electrical current to the motor windings to operate the stepper motor in one direction. The other 2 wires are also for 12 volts and ground to supply electrical current to operate the stepper motor in the opposite direction. To make the IAC go in the opposite direction, the PCM just reverses polarity on both windings. If only 1 wire is open, the IAC can only be moved 1 step (increment) in either direction. To keep the IAC motor in position when no movement is needed, the PCM will energize both windings at the same time. This locks the IAC motor in place. In the IAC motor system, the PCM will count every step that the motor is moved. This allows the PCM to determine the motor pintle position. If the memory is cleared, the PCM no longer knows the position of the pintle. So at the first key ON, the PCM drives the IAC motor closed, regardless of where it was before. This zeros the counter, From this point the PCM will back out the IAC motor and keep track of its position again. When engine rpm is above idle speed, the IAC is used for the following: - OFF-idle dashpot (throttle blade will close quickly but idle speed will not stop quickly) - Deceleration air flow control - A/C compressor load control (also opens the passage slightly before the compressor is engaged so that the engine rpm does not dip down when the compressor engages) - Power steering load control The PCM can control polarity of the circuit to control direction of the stepper motor. IAC Stepper Motor Program: The PCM is also equipped with a memory program that records the number of steps the IAC stepper motor most recently advanced to during a certain set of parameters. For example: The PCM was attempting to maintain a 1000 rpm target during a cold start-up cycle. The last recorded number of steps for that may have been 125. That value would be recorded in the memory cell so that the next time the PCM recognizes the identical conditions, the PCM recalls that 125 steps were required to maintain the target. This program allows for greater customer satisfaction due to greater control of engine idle. Another function of the memory program, which occurs when the power steering switch (if equipped), or the A/C request circuit, requires that the IAC stepper motor control engine rpm, is the recording of the last targeted steps into the memory cell. The PCM can anticipate A/C compressor loads. This is accomplished by delaying compressor operation for approximately 0.5 seconds until the PCM moves the IAC stepper motor to the recorded steps that were loaded into the memory cell. Using this program helps eliminate idle-quality changes as loads change. Finally, the PCM incorporates a "No-Load" engine speed limiter of approximately 1800 - 2000 rpm, when it recognizes that the TPS is indicating an idle signal and IAC motor cannot maintain engine idle. 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 IAC motor through the PCM. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 3038 Idle Air Control (IAC) Motor: Service and Repair REMOVAL Fig. 35 Throttle Body, Sensor And Electrical Connectors The IAC motor is located on the throttle body. 1. Remove air duct and air resonator box at throttle body. 2. Disconnect electrical connector from IAC motor. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 3039 Fig. 22 Mounting Bolts (Screws) - IAC Motor 3. Remove two mounting bolts (screws). 4. Remove IAC motor from throttle body. INSTALLATION 1. Install IAC motor to throttle body. 2. Install and tighten two mounting bolts (screws) to 7 Nm (60 in. lbs.) torque. 3. Install electrical connector. 4. Install air duct/air box to throttle body. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Auto Shut Down (ASD) Relay: Locations Power Distribution Center Automatic Shut Down Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3043 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3044 Auto Shut Down (ASD) Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3045 Automatic Shut Down Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3046 Auto Shut Down (ASD) Relay: Description and Operation AUTO SHUT DOWN RELAY PCM Output The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit ON and OFF. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. ASD Sense - PCM Input A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3047 Auto Shut Down (ASD) Relay: Testing and Inspection Fig. 1 ASD And Fuel Pump Relay Terminals - Type 1 Fig. 2 ASD And Fuel Pump Terminals - Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3048 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3049 Auto Shut Down (ASD) Relay: Service and Repair Fig. 3 Power Distribution Center (PDC) Location REMOVAL The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Power Distribution Center Fuel Pump Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3054 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3055 Fuel Pump Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3056 Fuel Pump Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3057 Fuel Pump Relay: Description and Operation The 5-pin, 12-volt, fuel pump relay is located in the Power Distribution Center (PDC). Refer to the label on the PDC cover for relay location. The Powertrain Control Module (PCM) energizes the electric fuel pump through the fuel pump relay. The fuel pump relay is energized by first applying battery voltage to it when the ignition key is turned ON, and then applying a ground signal to the relay from the PCM. Whenever the ignition key is turned ON, the electric fuel pump will operate. But, the PCM will shutdown the ground circuit to the fuel pump relay in approximately 1-3 seconds unless the engine is operating or the starter motor is engaged. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3058 Fuel Pump Relay: Testing and Inspection Fig. 1 ASD And Fuel Pump Relay Terminals - Type 1 Fig. 2 ASD And Fuel Pump Terminals - Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, (Fig. 1) or (Fig. 2). - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3059 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3060 Fuel Pump Relay: Service and Repair Fig. 21 Power Distribution Center (PDC) REMOVAL The fuel pump relay is located in the Power Distribution Center (PDC) (Fig. 21). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The fuel pump relay is located in the Power Distribution Center (PDC) (Fig. 21). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Auto Shut Down (ASD) Relay: Locations Power Distribution Center Automatic Shut Down Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3064 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3065 Auto Shut Down (ASD) Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3066 Automatic Shut Down Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3067 Auto Shut Down (ASD) Relay: Description and Operation AUTO SHUT DOWN RELAY PCM Output The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit ON and OFF. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. ASD Sense - PCM Input A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3068 Auto Shut Down (ASD) Relay: Testing and Inspection Fig. 1 ASD And Fuel Pump Relay Terminals - Type 1 Fig. 2 ASD And Fuel Pump Terminals - Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3069 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3070 Auto Shut Down (ASD) Relay: Service and Repair Fig. 3 Power Distribution Center (PDC) Location REMOVAL The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Locations Rollover Valve: Locations Fig. 37 Rollover Valve Locations The fuel tank is equipped with two rollover valves. The front valve is located on the top of the fuel pump module. The other valve is located on the top rear of the fuel tank. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Locations > Page 3074 Rollover Valve: Service Precautions WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING THE ROLLOVER VALVE(S), FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO FUEL PRESSURE RELEASE PROCEDURE. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Locations > Page 3075 Rollover Valve: Description and Operation Fig. 37 Rollover Valve Locations The fuel tank is equipped with two rollover valves. The front valve is located on the top of the fuel pump module (Fig. 37). The other valve is located on the top rear of the fuel tank (Fig. 37). The rollover valves will prevent fuel flow through the fuel tank vent (EVAP) hoses in the event of an accidental vehicle rollover. The EVAP canister draws fuel vapors from the fuel tank through these valves. The rear valve cannot be serviced separately. If replacement is necessary, the fuel tank must be replaced. Refer to Fuel Tank Removal/Installation. The front valve can be serviced separately. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Locations > Page 3076 Rollover Valve: Service and Repair Fig. 38 Rollover Valve Locations REMOVAL Two rollover valves are used. One of the valves is permanently mounted to top/rear of fuel tank (Fig. 38). If replacement of this particular valve is necessary, the fuel tank must be replaced. Refer to Fuel Tank Removal/Installation. The other rollover valve is located on top of the fuel pump module (Fig. 38). This valve may be serviced separately. Refer to following steps for procedures. WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING THE ROLLOVER VALVE(S), FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO FUEL PRESSURE RELEASE PROCEDURE. 1. Disconnect negative battery cable at battery. 2. Remove fuel filler cap and drain fuel tank. 3. Remove fuel tank. 4. Disconnect tube (line) at valve. 5. The rollover valve is seated into a rubber grommet. Remove valve by prying one side upward and then roll valve out of grommet. 6. Discard old grommet. INSTALLATION Two rollover valves are used. One of the valves is permanently mounted to top/rear of fuel tank (Fig. 38). If replacement of this particular valve is necessary, the fuel tank must be replaced. Refer to Fuel Tank Removal/Installation. The other rollover valve is located on top of the fuel pump module (Fig. 38). This valve may be serviced separately. Refer to following steps for procedures. 1. Install new grommet into fuel pump module. 2. Using finger pressure only, press valve into place. 3. Install fuel tank. Refer to Fuel Tank Installation. 4. Fill fuel tank. Install fuel tank filler cap. 5. Connect negative battery cable. 6. Start vehicle and check for leaks. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Mounting Screws ............................................................................................................................................... 7 Nm (60 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3081 Throttle Position Sensor: Locations The TPS is located on the throttle body. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3082 Throttle Position Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3083 Throttle Position Sensor: Description and Operation The 3-wire Throttle Position Sensor (TPS) is mounted on the throttle body and is connected to the throttle blade. The TPS is a 3-wire variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance (output voltage) of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from 0.26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: - Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - OFF-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3084 Throttle Position Sensor: Service and Repair REMOVAL The TPS is located on the throttle body. 1. Remove air duct and air resonator box at throttle body. Fig. 35 Throttle Body, Sensor And Electrical Connectors 2. Disconnect TPS electrical connector. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3085 Fig. 41 TPS Mounting Bolts 3. Remove two TPS mounting bolts (screws). 4. Remove TPS from throttle body. Fig. 43 TPS Installation Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3086 INSTALLATION The throttle shaft end of throttle body slides into a socket in TPS. The TPS must be installed so that it can be rotated a few degrees. If sensor will not rotate, install sensor with throttle shaft on other side of socket tangs. The TPS will be under slight tension when rotated. 1. Install TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 In. lbs.) torque. 3. Manually operate throttle control lever by hand to check for any binding of TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct/air box to throttle body. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations Throttle Body: Locations The throttle body is located on the intake manifold. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 3090 Throttle Body: Description and Operation The throttle body is located on the intake manifold. Fuel does not enter the intake manifold through the throttle body. Fuel is sprayed into the manifold by the fuel injectors. Filtered air from the air cleaner enters the intake manifold through the throttle body. The throttle body 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. Certain sensors are attached to the throttle body. The accelerator pedal cable, speed control cable and transmission control cable (when equipped) are connected to the throttle body linkage 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 PCM. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 3091 Throttle Body: Service and Repair REMOVAL 1. Remove the air duct and air resonator box at throttle body. Fig. 35 Throttle Body, Sensor And Electrical Connectors 2. Disconnect throttle body electrical connectors at IAC motor and TPS (Fig. 35). 3. Remove vacuum line at throttle body. 4. Remove all control cables from throttle body (lever) arm. Refer to Accelerator Pedal and Throttle Cable. 5. Remove three throttle body mounting bolts (Fig. 35). 6. Remove throttle body from intake manifold. INSTALLATION 1. Clean throttle body-to-intake manifold O-ring. 2. Clean mating surfaces of throttle body and intake manifold. 3. Install throttle body to intake manifold by positioning throttle body to manifold alignment pins. 4. Install three mounting bolts. Tighten bolts to 12 Nm (105 In. lbs.) torque. 5. Install control cables. 6. Install vacuum line to throttle body. 7. Install electrical connectors. 8. Install air duct/air box at throttle body. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair Throttle Cable/Linkage: Service and Repair REMOVAL CAUTION: Be careful not to damage or kink the cable core wire (within the cable sheathing) while servicing accelerator pedal or throttle cable. Fig. 13 Accelerator Pedal - Removal Or Installation 1. From inside vehicle, hold up accelerator pedal. Remove plastic cable retainer (clip) and throttle cable core wire from upper end of pedal arm (Fig. 13). Plastic cable retainer (clip) snaps into pedal arm. 2. Remove cable core wire at pedal arm. 3. From inside vehicle, remove clip holding cable to dashpanel (Fig. 13). 4. Remove air box at throttle body. 5. Unsnap cable from dashpanel routing clip. 6. Remove cable housing from dash panel and pull into engine compartment. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Page 3095 Fig. 36 Accelerator Cable At Bell Crank 7. Using finger pressure only, disconnect accelerator cable connector at throttle body bellcrank pin by pushing connector off bellcrank pin towards front of vehicle (Fig. 36). DO NOT try to pull connector off perpendicular to the bellcrank pin. Connector will be broken. 8. Lift accelerator cable from top of cable cam (Fig. 36) Fig. 37 Accelerator Cable Release Tab Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Page 3096 9. Press tab (Fig. 37) to release plastic cable mount from bracket. Press on tab only enough to release cable from bracket. If tab is pressed too much, it will be broken. Slide plastic mount (Fig. 37) towards passenger side of vehicle to remove cable from bracket. 10. Remove throttle cable from vehicle. INSTALLATION 1. Slide accelerator cable plastic mount into bracket. Continue sliding until tab (Fig. 37) is aligned to hole in mounting bracket. 2. Route accelerator cable over top of cable cam. 3. Connect cable end to throttle body bellcrank pin (snaps on rearward). 4. Slide rubber grommet away from plastic cable housing. 5. Install rubber grommet into dash panel until seated. 6. Push cable housing into rubber grommet and through opening in dash panel. 7. From inside vehicle, install clip holding cable to dashpanel (Fig. 13). 8. From inside vehicle, slide throttle cable core wire into opening in top of pedal arm. 9. Push cable retainer (clip) into pedal arm opening until it snaps in place. 10. Snap cable into dashpanel routing clip. 11. Install air box to throttle body. 12. Before starting engine, operate accelerator pedal to check for any binding. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Mounting Screws ............................................................................................................................................... 7 Nm (60 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3100 Throttle Position Sensor: Locations The TPS is located on the throttle body. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3101 Throttle Position Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3102 Throttle Position Sensor: Description and Operation The 3-wire Throttle Position Sensor (TPS) is mounted on the throttle body and is connected to the throttle blade. The TPS is a 3-wire variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance (output voltage) of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from 0.26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: - Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - OFF-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3103 Throttle Position Sensor: Service and Repair REMOVAL The TPS is located on the throttle body. 1. Remove air duct and air resonator box at throttle body. Fig. 35 Throttle Body, Sensor And Electrical Connectors 2. Disconnect TPS electrical connector. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3104 Fig. 41 TPS Mounting Bolts 3. Remove two TPS mounting bolts (screws). 4. Remove TPS from throttle body. Fig. 43 TPS Installation Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3105 INSTALLATION The throttle shaft end of throttle body slides into a socket in TPS. The TPS must be installed so that it can be rotated a few degrees. If sensor will not rotate, install sensor with throttle shaft on other side of socket tangs. The TPS will be under slight tension when rotated. 1. Install TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 In. lbs.) torque. 3. Manually operate throttle control lever by hand to check for any binding of TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct/air box to throttle body. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications ENGINE FIRING ORDER - 4.7L V-8 4.7L ENGINE DESCRIPTION Fig. 1 The 4.7 liter (287 CID) eight-cylinder engine is an 90° single overhead camshaft engine. The cast iron cylinder block is made up of two different components; the first component is the cylinder bore and upper block, the second component is the bedplate that comprises the lower portion of the cylinder block and houses the lower half of the crankshaft main bearings. The cylinders are numbered from front to rear with the left bank being numbered 1,3,5 and 7, and the right bank being numbered 2,4,6 and 8. The firing order is 1-8-4-3-6-5-7-2. The engine serial number is located at the Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Electrical Specifications > Page 3111 right front side of the engine block (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Electrical Specifications > Page 3112 Firing Order - 4.7L V-8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Firing Order - 4.7L V-8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor ................................................................................................................... ................................................... 12 Nm (106 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3120 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3121 Camshaft Position Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3122 Camshaft Position Sensor: Description and Operation Fig. 4 CMP Location The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. Fig. 5 CMP Sensor And Tonewheel The CMP sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects notches located on a tonewheel. The tonewheel is located at the front of the camshaft for the right cylinder head. As the tonewheel rotates, the notches pass through the sync signal generator. The pattern of the notches (viewed counter-clockwise from front of engine) is: 1 notch, 2 notches, 3 notches, 3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3123 notches, 2 notches 1 notch, 3 notches and 1 notch. The signal from the CMP sensor 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3124 Camshaft Position Sensor: Service and Repair Fig. 7 CMP Location REMOVAL The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. It is easier to remove/install sensor from under vehicle. 1. Raise and support vehicle. 2. Disconnect electrical connector at CMP sensor. 3. Remove sensor mounting bolt. 4. Carefully pry sensor from cylinder head in a rocking action with two small screwdrivers. 5. Check condition of sensor O-ring. INSTALLATION The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. 1. Clean out machined hole in cylinder head. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into cylinder head with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder head. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in. lbs.) torque. 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt .............................................................................................................................................................. 28 Nm (21 Ft. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 3128 Crankshaft Position Sensor: Locations Fig. 15 CKP Sensor Location The Crankshaft Position (CKP) sensor is located at the right-rear side of the engine cylinder block. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 3129 Crankshaft Position Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 3130 Crankshaft Position Sensor: Description and Operation Fig. 15 CKP Sensor Location The Crankshaft Position Sensor (CKP) is mounted into the right-rear side of the engine block. 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. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. Fig. 17 CKP Sensor Operation And Tonewheel Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 3131 On this engine, a tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 3132 Crankshaft Position Sensor: Service and Repair Fig. 19 CKP Sensor Location/Removal/Installation REMOVAL The Crankshaft Position (CKP) sensor is located at the right-rear side of the engine cylinder block. It is positioned and bolted into a machined hole in the engine block. 1. Disconnect CKP electrical connector at sensor. 2. Remove CKP mounting bolt. 3. Carefully pry sensor from cylinder block in a rocking action with two small screwdrivers. 4. Remove sensor from vehicle. 5. Check condition of sensor O-ring. INSTALLATION 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into engine block with a slight rocking action. Do not twist sensor into position as damage to O-ring may result CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 28 Nm (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Specifications Distributor: Specifications Distributor Holddown Bolt .................................................................................................................... .................................................. 23 Nm (17 Ft. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Specifications > Page 3136 Distributor: Service Precautions WARNING: WHEN PERFORMING THE FOLLOWING TEST, THE ENGINE WILL BE RUNNING. BE CAREFUL NOT TO STAND IN LINE WITH THE FAN BLADES OR FAN BELT. DO NOT WEAR LOOSE CLOTHING. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Electrical Specifications Ignition Coil Resistance Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Electrical Specifications > Page 3141 Ignition Coil: Mechanical Specifications Ignition Coil Mounting Nut ................................................................................................................... .................................................... 8 Nm (70 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3142 Ignition Coil: Locations Fig. 19 Ignition Coil Location Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3143 Ignition Coil: Diagrams Coil On Plug No.1 Coil On Plug No.2 Coil On Plug No.3 Coil On Plug No.4 Coil On Plug No.5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3144 Coil On Plug No.6 Coil On Plug No.7 Coil On Plug No.8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3145 Ignition Coil: Description and Operation Fig. 15 Ignition Coil Fig. 16 Ignition Coil Location This engine uses 8 dedicated, and individually fired coil for each spark plug. Each coil is mounted directly to the top of each spark plug. Battery voltage is supplied to the 8 ignition coils from the ASD relay. The Powertrain Control Module (PCM) opens and closes each ignition coil ground circuit at a determined time for ignition coil operation. Base ignition timing is not adjustable. 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. 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3146 Because of coil design, spark plug cables (secondary cables) are not used. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3147 Ignition Coil: Service and Repair Fig. 18 Ignition Coil Fig. 19 Ignition Coil Location REMOVAL An individual ignition coil is used for each spark plug. The coil fits into machined holes in the cylinder head. A mounting stud/nut secures each coil to the top of the intake manifold. The bottom of the coil is equipped with a rubber boot to seal the spark plug to the coil. Inside each rubber boot is a spring. The spring is used for a mechanical contact between the coil and the top of the spark plug. These rubber boots and springs are a permanent part of the coil and are not serviced separately. An O-ring is used to seal the coil at the opening into the cylinder head. 1. Depending on which coil is being removed, the throttle body air intake tube or intake box may need to be removed to gain access to coil. 2. Disconnect electrical connector from coil by pushing downward on release lock on top of connector and pull connector from coil. 3. Clean area at base of coil with compressed air before removal. 4. Remove coil mounting nut from mounting stud. 5. Carefully pull up coil from cylinder head opening with a slight twisting action. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3148 6. Remove coil from vehicle. INSTALLATION 1. Using compressed air, blow out any dirt or contaminants from around top of spark plug. 2. Check condition of coil O-ring and replace as necessary. To aid in coil installation, apply silicone to coil O-ring. 3. Position ignition coil into cylinder head opening and push onto spark plug. Do this while guiding coil base over mounting stud. 4. Install mounting stud nut and tighten to 8 Nm (70 in. lbs.) torque. 5. Connect electrical connector to coil by snapping into position. 6. If necessary, install throttle body air tube or box. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor ................................................................................................................... ................................................... 12 Nm (106 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3153 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3154 Camshaft Position Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3155 Camshaft Position Sensor: Description and Operation Fig. 4 CMP Location The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. Fig. 5 CMP Sensor And Tonewheel The CMP sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects notches located on a tonewheel. The tonewheel is located at the front of the camshaft for the right cylinder head. As the tonewheel rotates, the notches pass through the sync signal generator. The pattern of the notches (viewed counter-clockwise from front of engine) is: 1 notch, 2 notches, 3 notches, 3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3156 notches, 2 notches 1 notch, 3 notches and 1 notch. The signal from the CMP sensor 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3157 Camshaft Position Sensor: Service and Repair Fig. 7 CMP Location REMOVAL The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. It is easier to remove/install sensor from under vehicle. 1. Raise and support vehicle. 2. Disconnect electrical connector at CMP sensor. 3. Remove sensor mounting bolt. 4. Carefully pry sensor from cylinder head in a rocking action with two small screwdrivers. 5. Check condition of sensor O-ring. INSTALLATION The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. 1. Clean out machined hole in cylinder head. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into cylinder head with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder head. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in. lbs.) torque. 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolt .............................................................................................................................................................. 28 Nm (21 Ft. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 3161 Crankshaft Position Sensor: Locations Fig. 15 CKP Sensor Location The Crankshaft Position (CKP) sensor is located at the right-rear side of the engine cylinder block. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 3162 Crankshaft Position Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 3163 Crankshaft Position Sensor: Description and Operation Fig. 15 CKP Sensor Location The Crankshaft Position Sensor (CKP) is mounted into the right-rear side of the engine block. 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. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. Fig. 17 CKP Sensor Operation And Tonewheel Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 3164 On this engine, a tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 3165 Crankshaft Position Sensor: Service and Repair Fig. 19 CKP Sensor Location/Removal/Installation REMOVAL The Crankshaft Position (CKP) sensor is located at the right-rear side of the engine cylinder block. It is positioned and bolted into a machined hole in the engine block. 1. Disconnect CKP electrical connector at sensor. 2. Remove CKP mounting bolt. 3. Carefully pry sensor from cylinder block in a rocking action with two small screwdrivers. 4. Remove sensor from vehicle. 5. Check condition of sensor O-ring. INSTALLATION 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into engine block with a slight rocking action. Do not twist sensor into position as damage to O-ring may result CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 28 Nm (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications Spark Plug: Specifications Plug Gap .............................................................................................................................................. .................................................... 1.01 mm (0.040 in.) Tightening Torque ............................................................................................................................... ...................................................... 27 Nm (20 ft. lbs.) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3169 Spark Plug: Locations The spark plug is located under each ignition coil. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3170 Spark Plug: Application and ID Plug Type ............................................................................................................................................ ............................................................... RC12MCC4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3171 Spark Plug: Description and Operation This engine are equipped with "fired in suppressor seal" type spark plugs using a copper core ground electrode. Because of the use of an aluminum cylinder head on this engine, spark plug torque is very critical. To prevent possible pre-ignition and/or mechanical engine damage, the correct type/heat range/number spark plug must be used. 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 intervals recommended in Lubrication and Maintenance. Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or oil fouled. Also refer to Spark Plug Conditions. 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3172 Spark Plug: Testing and Inspection SPARK PLUG CONDITIONS Fig. 20 Normal Operation And Cold (Carbon) Fouling Normal Operating 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. On this engine gap growth will not average more than approximately 0.0015 in per 3200 km (2000 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 may be affected by MMT deposits. Cold Fouling/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 cleaner element or repeated short operating times (short trips). 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3173 Fig. 21 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. Fig. 22 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3174 Fig. 23 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 fuses. 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. Fig. 24 Chipped Electrode 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3175 Fig. 25 Preignition Damage 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.) Fig. 26 Spark Plug 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 2000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions can also cause spark plug overheating. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3176 Spark Plug: Service and Repair REMOVAL 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. In this engine: Each individual spark plug is located under each ignition coil. Each individual ignition coil must be removed to gain access to each spark plug. Refer to Ignition Coil Removal/Installation. 1. In this engine: Prior to removing spark plug, spray compressed air around base of ignition coil at cylinder head. This will help prevent foreign material from entering combustion chamber. 2. Remove spark plug from cylinder head using a quality socket with a rubber or foam insert. If equipped with this engine, also check condition of coil O-ring and replace as necessary. 3. Inspect spark plug condition. Refer to Spark Plug Conditions. CLEANING The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean spark plugs. Metallic deposits will remain on spark plug insulator and will cause plug misfire. INSTALLATION CAUTION: This engine is equipped with copper core ground electrode spark plugs. They must be replaced with the same type/number spark plug as the original. If another spark plug is substituted, pre-ignition will result. 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. 1. Start the spark plug into the cylinder head by hand to avoid cross threading. 2. In this engine: Tighten spark plugs to 27 Nm (20 ft. lbs.) torque. 3. In this engine: Before installing coil(s), check condition of coil O-ring and replace as necessary. To aid in coil installation, apply silicone to coil O-ring. 4. In this engine: Install ignition coil(s). Refer to Ignition Coil Removal/Installation. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Service and Repair Shift Solenoid: Service and Repair REMOVAL 1. Remove the valve body from the transmission (Fig. 116). 2. Remove the screws holding the transmission solenoid/TRS assembly onto the valve body (Fig. 117). 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the screws to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 5.7 Nm (50 inch lbs.). 5. Tighten the remainder of the solenoid assembly screws to 5.7 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance Torque Converter Clutch Solenoid: Customer Interest MIL ON - TCC/OD Solenoid Performance NUMBER: 21-11-00 GROUP: Transmissions EFFECTIVE DATE: October 02, 2000 SUBJECT: 46RE Transmission MIL Due To DTC P1740 - TCC or OD Solenoid Performance OVERVIEW: This bulletin involves the replacement of the transmission pressure boost valve cover plate. MODELS: 2000 - 2001 (AB) Ram Van 2000 - 2001 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 - 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 46RE TRANSMISSION BUILT BEFORE AUGUST 01, 2000 (MDH O8O1XX). SYMPTOM/CONDITION: The customer may complain of a Malfunction Indicator Lamp (MIL) illumination. Upon further analysis, it is determined that the MIL is caused by Diagnostic Trouble Code (DTC) P1740 - Torque Converter Clutch (TCC) or Overdrive Solenoid Performance. Other than the MIL, the customer may not notice any other condition with the transmission. This condition may be caused by an intermittent and momentary TCC disengagement condition. The transmission valve body pressure boost valve cover plate has been revised with a larger size orifice hole to address this condition. DIAGNOSIS: 1. Warm the transmission to normal operating temperatures. 2. Using the DRB III(R), perform a torque converter clutch (TCC) stall test. The stall test has been revised so that the TCC remains engaged for a period of four (4) seconds. NOTE: THE DRB III(R) MUST BE OPERATING AT RELEASE LEVEL 50.4 MDS2 SYSTEM CIS CD2067 OR HIGHER (AVAILABLE THE WEEK OF OCTOBER 2, 2000) IN ORDER TO PERFORM THE REVISED TORQUE CONVERTER CLUTCH STALL TEST. DO NOT USE EARLIER VERSION STALL TEST TO DETERMINE CONDITION OF THE TORQUE CONVERTER CLUTCH. 3. If the engine stalls as a result of the TCC stall test, then perform the Repair Procedure. 4. If the engine does not stall, as a result of the TCC stall test, then further diagnosis is required. The technician may want to consider the following components during their additional diagnosis: a cut or worn input shaft seals, a missing pump lock-up circuit check ball, or worn converter hub, input shaft, reaction shaft, and pump rotor. PARTS REQUIRED: REPAIR PROCEDURE: 1. Clean the pressure boost valve cover plate to remove any dirt or rust inhibitor prior to installation. The revised cover plate will have a 1.75 mm (0.069 inch) orifice hole versus a 1.22 mm (0.048 inch) orifice hole in the original plate. Make sure it is clean. 2. Using the appropriate Service Manual, Group 21 - Transmissions and Transfer Case, replace the transmission pressure boost valve cover plate p/n Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance > Page 3194 04617012. 3. Verify fluid level after warming up the transmission and cycling the shift lever several times. 4. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance Torque Converter Clutch Solenoid: All Technical Service Bulletins MIL ON - TCC/OD Solenoid Performance NUMBER: 21-11-00 GROUP: Transmissions EFFECTIVE DATE: October 02, 2000 SUBJECT: 46RE Transmission MIL Due To DTC P1740 - TCC or OD Solenoid Performance OVERVIEW: This bulletin involves the replacement of the transmission pressure boost valve cover plate. MODELS: 2000 - 2001 (AB) Ram Van 2000 - 2001 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 - 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 46RE TRANSMISSION BUILT BEFORE AUGUST 01, 2000 (MDH O8O1XX). SYMPTOM/CONDITION: The customer may complain of a Malfunction Indicator Lamp (MIL) illumination. Upon further analysis, it is determined that the MIL is caused by Diagnostic Trouble Code (DTC) P1740 - Torque Converter Clutch (TCC) or Overdrive Solenoid Performance. Other than the MIL, the customer may not notice any other condition with the transmission. This condition may be caused by an intermittent and momentary TCC disengagement condition. The transmission valve body pressure boost valve cover plate has been revised with a larger size orifice hole to address this condition. DIAGNOSIS: 1. Warm the transmission to normal operating temperatures. 2. Using the DRB III(R), perform a torque converter clutch (TCC) stall test. The stall test has been revised so that the TCC remains engaged for a period of four (4) seconds. NOTE: THE DRB III(R) MUST BE OPERATING AT RELEASE LEVEL 50.4 MDS2 SYSTEM CIS CD2067 OR HIGHER (AVAILABLE THE WEEK OF OCTOBER 2, 2000) IN ORDER TO PERFORM THE REVISED TORQUE CONVERTER CLUTCH STALL TEST. DO NOT USE EARLIER VERSION STALL TEST TO DETERMINE CONDITION OF THE TORQUE CONVERTER CLUTCH. 3. If the engine stalls as a result of the TCC stall test, then perform the Repair Procedure. 4. If the engine does not stall, as a result of the TCC stall test, then further diagnosis is required. The technician may want to consider the following components during their additional diagnosis: a cut or worn input shaft seals, a missing pump lock-up circuit check ball, or worn converter hub, input shaft, reaction shaft, and pump rotor. PARTS REQUIRED: REPAIR PROCEDURE: 1. Clean the pressure boost valve cover plate to remove any dirt or rust inhibitor prior to installation. The revised cover plate will have a 1.75 mm (0.069 inch) orifice hole versus a 1.22 mm (0.048 inch) orifice hole in the original plate. Make sure it is clean. 2. Using the appropriate Service Manual, Group 21 - Transmissions and Transfer Case, replace the transmission pressure boost valve cover plate p/n Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance > Page 3200 04617012. 3. Verify fluid level after warming up the transmission and cycling the shift lever several times. 4. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Technical Service Bulletins > Page 3201 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Overdrive Indicator Lamp: Locations The Overdrive OFF Indicator (VFD) is part of the cluster electronic circuit board, and is visible through a cutout located in the lower right corner of the cluster overlay. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3207 Overdrive Indicator Lamp: Description and Operation OVERDRIVE OFF INDICATOR An overdrive OFF indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional overdrive automatic transmission, this indicator is electronically disabled. The overdrive OFF indicator consists of the text "O/D OFF", which appears in the lower portion of the electronic gear selector indicator Vacuum Fluorescent Display (VFD). The VFD is part of the cluster electronic circuit board, and is visible through a cutout located in the lower right corner of the cluster overlay. The dark lens of the VFD prevents the indicator from being clearly visible when it is not illuminated. The text "O/D OFF" appears in an amber color and at the same lighting level as the gear selector indicator information when it is illuminated by the instrument cluster electronic circuit board. The overdrive OFF indicator is serviced as a unit with the VFD in the instrument cluster. The overdrive OFF indicator gives an indication to the vehicle operator when the OFF position of the overdrive OFF switch has been selected, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The overdrive OFF indicator receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions; therefore, the indicator will always be OFF when the ignition switch is in any position except ON or Start. The indicator only illuminates when it is switched to ground by the instrument cluster circuitry. The instrument cluster will turn ON the overdrive OFF indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the overdrive OFF indicator is illuminated for about two seconds as a bulb test. - Overdrive OFF Lamp-ON Message - Each time the cluster receives an overdrive OFF lamp-ON message from the PCM indicating that the OFF position of the overdrive OFF switch has been selected, the overdrive OFF indicator will be illuminated. The indicator remains illuminated until the cluster receives an overdrive OFF lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the overdrive OFF indicator will be turned ON, then OFF again during the VFD portion of the test to confirm the functionality of the VFD, and again during the bulb check portion of the test to confirm the functionality of the cluster control circuitry. The PCM continually monitors the overdrive OFF switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper overdrive OFF lamp-ON and lamp-OFF messages to the instrument cluster. For further diagnosis of the overdrive OFF indicator or the instrument cluster circuitry that controls the indicator, (Refer to INSTRUMENT/CLUSTER DIAGNOSIS AND TESTING). For proper diagnosis of the overdrive control system, the PCM, the PCI data bus, or the message inputs to the instrument cluster that control the overdrive OFF indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair Shift Indicator: Service and Repair GEARSHIFT INDICATOR REMOVAL The following service procedures apply only to the mechanical gear selector indicator. The electronic gear selector indicator is integral to the instrument cluster and can only be serviced by replacement of the instrument cluster unit. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument cluster from the instrument panel. Fig. 13 3. Remove the two screws that secure the gear selector indicator mechanism to the back of the instrument cluster housing (Fig. 13). 4. Remove the gear selector indicator mechanism from the back of the instrument cluster housing. 5. Remove the steering column opening cover from the instrument panel. Fig. 14 6. Disengage the loop end of the gear selector indicator cable from the lever on the left side of the steering column (Fig. 14). 7. Squeeze the sides of the plastic adjuster and bracket unit to disengage the tabs that secure it to the sides of the steering column window. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair > Page 3211 8. Remove the gear selector indicator mechanism and cable unit from the instrument panel. INSTALLATION The following service procedures apply only to the mechanical gear selector indicator. The electronic gear selector indicator is integral to the instrument cluster and can only be serviced by replacement of the instrument cluster unit. 1. Position the gear selector indicator mechanism and cable unit to the instrument panel. 2. Squeeze the sides of the plastic adjuster and bracket unit and engage the tabs that secure it with the sides of the steering column window. 3. Engage the loop end of the gear selector indicator cable onto the lever on the left side of the steering column (Fig. 14). 4. Position the gear selector indicator mechanism onto the back of the instrument cluster housing. 5. Install and tighten the two screws that secure the gear selector indicator mechanism to the back of the instrument cluster housing. Tighten the screws to 2.2 N.m (20 in. lbs.). 6. Install the instrument cluster onto the instrument panel. 7. Check the gear selector indicator for proper calibration. If adjustment is needed, 8. Install the steering column opening cover onto the instrument panel. 9. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Locations Temperature Warning Indicator - A/T: Locations The transmission over-temperature indicator is located in the Information Center area of the instrument cluster, to the left of center. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Locations > Page 3215 Temperature Warning Indicator - A/T: Description and Operation A transmission over-temperature indicator lamp is standard equipment on all instrument clusters. The transmission over-temperature indicator is located in the Information Center area of the instrument cluster, to the left of center. The transmission over-temperature indicator consists of a stencilled cutout of the words "TRANS TEMP" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red lens behind the cutout in the opaque layer of the overlay causes the "TRANS TEMP" text to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by a Light Emitting Diode (LED) soldered onto the instrument cluster electronic circuit board. The transmission overtemperature indicator is serviced as a unit with the instrument cluster. The transmission over-temperature indicator gives an indication to the vehicle operator when the trans- mission fluid temperature is excessive, which may lead to accelerated transmission component wear or failure. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The transmission over-temperature indicator Light Emitting Diode (LED) receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions; therefore, the LED will always be OFF when the ignition switch is in any position except ON or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the transmission over-temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the transmission over-temperature indicator is illuminated for about two seconds as a bulb test. - Trans Over-Temp Lamp-ON Message - Each time the cluster receives a trans over-temp lamp-ON message from the PCM indicating that the transmission fluid temperature is 135 °C (275 °F) or higher, the indicator will be illuminated and a single chime tone is sounded. The lamp remains illuminated until the cluster receives a trans over-temp lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the transmission over-temperature indicator is cycled OFF and then on again by the appropriate trans over-temp messages from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition, then sends the proper messages to the instrument cluster. If the instrument cluster turns ON the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission and/or the transmission cooling system are being overloaded or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the transmission temperature sensor, the PCM, the PCI data bus, or the message inputs to the instrument cluster that control the transmission over-temperature indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle Technical Service Bulletin # 08-032-00A Date: 001229 4X4 Service Lamp - ON, 4X2 Vehicle NUMBER: 08-032-00 REV. A GROUP: Electrical DATE: Dec. 29, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-032-00, DATED OCTOBER 20, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS BULLETIN IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS SUBJECT: "Service 4WD" Lamp Illuminated On 4X2 Vehicles OVERVIEW: This bulletin involves installing a revised HVAC control assembly. MODELS: NOTE: THIS BULLETIN APPLIES TO 4X2 VEHICLES BUILT BEFORE OCTOBER 13, 2000 (MDH 1013XX). SYMPTOM/CONDITION: The "Service 4WD" lamp is illuminated even though the truck is not a 4X4 vehicle. DIAGNOSIS: Start the engine. Once the instrument cluster bulb check has been completed, verify that the "Service 4WD" lamp is illuminated. If the "Service 4WD" lamp is illuminated, perform the Repair Procedure. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 3225 FAILURE CODE: Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING INSTRUMENT PANEL COMPONENT SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is equipped with an automatic transmission, turn the ignition switch to the Unlock position, set the park brake, and place the transmission gear selector lever in the LOW position. 3. If the vehicle is equipped with a tilt column, set the tilt steering column in its lowest position. 4. Reach under the left end of the instrument panel to access and unsnap the rod end clip on the park brake release link and disengage the link from the back of the handle (Fig. 1). 5. Remove the three screws that secure the lower edge of the steering column opening cover to the lower instrument panel reinforcement. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 3226 6. Using a trim stick or another suitable wide flat-bladed tool, gently pry the upper edge of the steering column opening cover just below the cluster bezel on each side of the steering column away from the instrument panel far enough to disengage each of the snap clip retainers from their receptacles in the instrument panel base trim (Fig. 2). 7. Remove the steering column opening cover from the instrument panel. 8. Remove the two screws in the hooded area above the instrument cluster that secures the cluster bezel to the instrument panel base trim (Fig. 3). 9. Using a trim stick or another suitable wide flat-bladed tool, gently pry around the perimeter of the cluster bezel to disengage the snap clips from their receptacles in the instrument panel base trim. 10. Pull the right side of the cluster bezel away from the instrument panel far enough to access and disconnect the instrument panel wire harness connector for the headlamp switch from the switch connector receptacle. 11. Pull the left side of the cluster bezel away from the instrument panel far enough to access and disconnect the instrument panel wire harness connectors from the receptacles for the passenger airbag ON/OFF switch (if equipped), the rear window defogger switch (if equipped), the HVAC control, and the transfer case switch (if equipped). 12. Remove the cluster bezel from the instrument panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 3227 13. Remove the four screws that secure the HVAC control to the cluster bezel (Fig. 4). 14. Remove the HVAC control from the instrument panel. 15. Position the new HVAC control (see Parts Required section) in the cluster bezel and secure it with four screws. Tighten the screws to 2.2 Nm (17 i3 in. lbs.) 16. Position the cluster bezel to the instrument panel. 17. Pull the left side of the cluster bezel away from the instrument panel far enough to access and reconnect the instrument panel wire harness connectors to the receptacles for the passenger airbag on/off switch (if equipped), the rear window defogger switch (if equipped), the HVAC control, and the transfer case switch (if equipped). 18. Pull the right side of the cluster bezel away from the instrument panel far enough to access and reconnect the instrument panel wire harness connector for the headlamp switch to the switch connector receptacle. 19. Align the snap clips on the cluster bezel with the receptacles in the instrument panel base trim. 20. Using hand pressure, press firmly on the cluster bezel over each of the snap clip locations until each snap clip is fully engaged in their receptacle. 21. Install and tighten the two screws in the hooded area above the instrument cluster that secure the cluster bezel to the instrument panel base trim (Fig. 3). Tighten the screws to 2.2 Nm (20 in. lbs.). 22. Position the steering column opening cover to the instrument panel. 23. Align the snap clip retainers on the steering column opening cover with the receptacles in the instrument panel base trim. 24. Using hand pressure, press firmly on the steering column opening cover over the snap clip locations until each of the snap clips are fully engaged in their receptacle. 25. Install and tighten the three screws that secure the lower edge of the steering column opening cover to the instrument structural support. Tighten the screws to 2.2 Nm (20 in.lbs.). 26. Reach under the left end of the instrument panel to access and engage the park brake release link to the back of the handle. Then snap the rod end clip over the park brake release link to secure the connection. 27. Reconnect the battery negative cable. 28. On vehicles equipped with A/C, perform the A/C cool down test using the DRBIII(R). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle Technical Service Bulletin # 08-032-00A Date: 001229 4X4 Service Lamp - ON, 4X2 Vehicle NUMBER: 08-032-00 REV. A GROUP: Electrical DATE: Dec. 29, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-032-00, DATED OCTOBER 20, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS BULLETIN IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS SUBJECT: "Service 4WD" Lamp Illuminated On 4X2 Vehicles OVERVIEW: This bulletin involves installing a revised HVAC control assembly. MODELS: NOTE: THIS BULLETIN APPLIES TO 4X2 VEHICLES BUILT BEFORE OCTOBER 13, 2000 (MDH 1013XX). SYMPTOM/CONDITION: The "Service 4WD" lamp is illuminated even though the truck is not a 4X4 vehicle. DIAGNOSIS: Start the engine. Once the instrument cluster bulb check has been completed, verify that the "Service 4WD" lamp is illuminated. If the "Service 4WD" lamp is illuminated, perform the Repair Procedure. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 3233 FAILURE CODE: Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING INSTRUMENT PANEL COMPONENT SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is equipped with an automatic transmission, turn the ignition switch to the Unlock position, set the park brake, and place the transmission gear selector lever in the LOW position. 3. If the vehicle is equipped with a tilt column, set the tilt steering column in its lowest position. 4. Reach under the left end of the instrument panel to access and unsnap the rod end clip on the park brake release link and disengage the link from the back of the handle (Fig. 1). 5. Remove the three screws that secure the lower edge of the steering column opening cover to the lower instrument panel reinforcement. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 3234 6. Using a trim stick or another suitable wide flat-bladed tool, gently pry the upper edge of the steering column opening cover just below the cluster bezel on each side of the steering column away from the instrument panel far enough to disengage each of the snap clip retainers from their receptacles in the instrument panel base trim (Fig. 2). 7. Remove the steering column opening cover from the instrument panel. 8. Remove the two screws in the hooded area above the instrument cluster that secures the cluster bezel to the instrument panel base trim (Fig. 3). 9. Using a trim stick or another suitable wide flat-bladed tool, gently pry around the perimeter of the cluster bezel to disengage the snap clips from their receptacles in the instrument panel base trim. 10. Pull the right side of the cluster bezel away from the instrument panel far enough to access and disconnect the instrument panel wire harness connector for the headlamp switch from the switch connector receptacle. 11. Pull the left side of the cluster bezel away from the instrument panel far enough to access and disconnect the instrument panel wire harness connectors from the receptacles for the passenger airbag ON/OFF switch (if equipped), the rear window defogger switch (if equipped), the HVAC control, and the transfer case switch (if equipped). 12. Remove the cluster bezel from the instrument panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 3235 13. Remove the four screws that secure the HVAC control to the cluster bezel (Fig. 4). 14. Remove the HVAC control from the instrument panel. 15. Position the new HVAC control (see Parts Required section) in the cluster bezel and secure it with four screws. Tighten the screws to 2.2 Nm (17 i3 in. lbs.) 16. Position the cluster bezel to the instrument panel. 17. Pull the left side of the cluster bezel away from the instrument panel far enough to access and reconnect the instrument panel wire harness connectors to the receptacles for the passenger airbag on/off switch (if equipped), the rear window defogger switch (if equipped), the HVAC control, and the transfer case switch (if equipped). 18. Pull the right side of the cluster bezel away from the instrument panel far enough to access and reconnect the instrument panel wire harness connector for the headlamp switch to the switch connector receptacle. 19. Align the snap clips on the cluster bezel with the receptacles in the instrument panel base trim. 20. Using hand pressure, press firmly on the cluster bezel over each of the snap clip locations until each snap clip is fully engaged in their receptacle. 21. Install and tighten the two screws in the hooded area above the instrument cluster that secure the cluster bezel to the instrument panel base trim (Fig. 3). Tighten the screws to 2.2 Nm (20 in. lbs.). 22. Position the steering column opening cover to the instrument panel. 23. Align the snap clip retainers on the steering column opening cover with the receptacles in the instrument panel base trim. 24. Using hand pressure, press firmly on the steering column opening cover over the snap clip locations until each of the snap clips are fully engaged in their receptacle. 25. Install and tighten the three screws that secure the lower edge of the steering column opening cover to the instrument structural support. Tighten the screws to 2.2 Nm (20 in.lbs.). 26. Reach under the left end of the instrument panel to access and engage the park brake release link to the back of the handle. Then snap the rod end clip over the park brake release link to secure the connection. 27. Reconnect the battery negative cable. 28. On vehicles equipped with A/C, perform the A/C cool down test using the DRBIII(R). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > Customer Interest for Transmission Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts Transmission Control Module: Customer Interest A/T - 45RFE/545RFE Harsh Upshifts/Downshifts NUMBER: 18-025-01 GROUP: Vehicle Performance DATE: October 15, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-09-00, DATED SEPTEMBER 15, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. **ASTERISKS** HAVE BEEN USED TO HIGHLIGHT CHANGES. THIS BULLETIN ADDS A MODEL YEAR AND REQUIRES A REPROGRAMMING OF THE 1999 AND 2000 GRAND CHEROKEE POWERTRAIN CONTROL MODULE (PCM). SUBJECT: 45RFE **and 545RFE Shift** Quality Enhancements for the** 2-3, 4-5, and 5-4** Shifts OVERVIEW: This bulletin involves selectively erasing and reprogramming the **Transmission Control Module (TCM) with new software: '99-'01 WJ (PN 05019701AC Ver 9.3), '00 AN/DN (PN 05018454AB Ver 9.1), or '01 AN/DN (PN 56028285A1 Ver 8.4), and requires reprogramming of the Powertrain Control Module (PCM) for the 1999 and 2000 Grand Cherokees only (with calibration 99Cal20 (1999) or 00Cal17 (2000).** NOTE: THE 2001 GRAND CHEROKEE DOES NOT REQUIRE REPROGRAMMING OF THE PCM AS IT IS ALREADY AT THE CORRECT CALIBRATION LEVEL. NOTE: WHENEVER A PCM OR TCM IS REPLACED OR REPROGRAMMED, THE SOFTWARE OF THE PCM MUST BE VERIFIED AS HAVING THE LATEST REVISION LEVEL. MODELS: 2000 (AN) Dakota **2001** 2000 (DN) Durango **2001** 1999 (WJ) Grand Cherokee **2001 ** NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 4.7L ENGINE AND A 45RFE **OR 545RFE** TRANSMISSION. SYMPTOM/CONDITION: Some vehicles **may exhibit one or more of the following performance conditions **: 1. A harsh 2-3 upshift causing a powertrain clunk or shudder when accelerating. 2. **A harsh 4-5 upshift ('01 Grand Cherokee only).** 3. **A harsh 5-4 downshift ('01 Grand Cherokee only).** NOTE: THIS REVISION TO THE TCM SOFTWARE ADDRESSES THE ABOVE SHIFT QUALITY CONDITIONS FOR ALL VEHICLES AND, ADDS A FINAL GEAR RATIO TO THE **1999 AND 2000 MY** GRAND CHEROKEE TRANSMISSION ONLY. (2001 MY GRAND CHEROKEE ALREADY HAS THIS UPGRADE.) NOTE: TO MAINTAIN EMISSIONS COMPLIANCE, GRAND CHEROKEE VEHICLES THAT ARE EQUIPPED WITH A FEDERAL EMISSION SYSTEM (SALES CODE NAA) MUST HAVE THEIR PCM REPROGRAMMED. IF THE SOFTWARE LEVEL IS AT OR HIGHER THAN THOSE IN THE OVERVIEW ABOVE, OR IF THE GRAND CHEROKEE HAS A CALIFORNIA EMISSIONS SYSTEM (SALES CODE NAE), REPROGRAMMING IS NOT NECESSARY. DIAGNOSIS PROCEDURES: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRBIII(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 performing this repair. If no DTC's are present, and the above symptom has been experienced, perform the Repair Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > Customer Interest for Transmission Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts > Page 3246 Procedure. NOTE: **IF OTHER PERFORMANCE ISSUES REMAIN AFTER THE REPAIR PROCEDURE HAS BEEN PERFORMED THEY DO NOT RELATE TO THIS BULLETIN. REFER TO THE PROPER SERVICE OR DIAGNOSTIC PROCEDURES MANUAL(S) FOR FURTHER ASSISTANCE.** PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD **2093 OR HIGHER AND DRB III(R) VERSION 52.3 WILL BE IN THE DEALERSHIPS ON OCTOBER 15, 2001.)** REPAIR PROCEDURE: 1. Log onto the MDS2 (Mopar Diagnostic System). 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III(R), MDS2, AND VEHICLE ESTABLISH COMMUNICATION. 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. 3. Push the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) 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. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. 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, 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 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > Customer Interest for Transmission Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts > Page 3247 7. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 8. 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts Transmission Control Module: All Technical Service Bulletins A/T - 45RFE/545RFE Harsh Upshifts/Downshifts NUMBER: 18-025-01 GROUP: Vehicle Performance DATE: October 15, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-09-00, DATED SEPTEMBER 15, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. **ASTERISKS** HAVE BEEN USED TO HIGHLIGHT CHANGES. THIS BULLETIN ADDS A MODEL YEAR AND REQUIRES A REPROGRAMMING OF THE 1999 AND 2000 GRAND CHEROKEE POWERTRAIN CONTROL MODULE (PCM). SUBJECT: 45RFE **and 545RFE Shift** Quality Enhancements for the** 2-3, 4-5, and 5-4** Shifts OVERVIEW: This bulletin involves selectively erasing and reprogramming the **Transmission Control Module (TCM) with new software: '99-'01 WJ (PN 05019701AC Ver 9.3), '00 AN/DN (PN 05018454AB Ver 9.1), or '01 AN/DN (PN 56028285A1 Ver 8.4), and requires reprogramming of the Powertrain Control Module (PCM) for the 1999 and 2000 Grand Cherokees only (with calibration 99Cal20 (1999) or 00Cal17 (2000).** NOTE: THE 2001 GRAND CHEROKEE DOES NOT REQUIRE REPROGRAMMING OF THE PCM AS IT IS ALREADY AT THE CORRECT CALIBRATION LEVEL. NOTE: WHENEVER A PCM OR TCM IS REPLACED OR REPROGRAMMED, THE SOFTWARE OF THE PCM MUST BE VERIFIED AS HAVING THE LATEST REVISION LEVEL. MODELS: 2000 (AN) Dakota **2001** 2000 (DN) Durango **2001** 1999 (WJ) Grand Cherokee **2001 ** NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 4.7L ENGINE AND A 45RFE **OR 545RFE** TRANSMISSION. SYMPTOM/CONDITION: Some vehicles **may exhibit one or more of the following performance conditions **: 1. A harsh 2-3 upshift causing a powertrain clunk or shudder when accelerating. 2. **A harsh 4-5 upshift ('01 Grand Cherokee only).** 3. **A harsh 5-4 downshift ('01 Grand Cherokee only).** NOTE: THIS REVISION TO THE TCM SOFTWARE ADDRESSES THE ABOVE SHIFT QUALITY CONDITIONS FOR ALL VEHICLES AND, ADDS A FINAL GEAR RATIO TO THE **1999 AND 2000 MY** GRAND CHEROKEE TRANSMISSION ONLY. (2001 MY GRAND CHEROKEE ALREADY HAS THIS UPGRADE.) NOTE: TO MAINTAIN EMISSIONS COMPLIANCE, GRAND CHEROKEE VEHICLES THAT ARE EQUIPPED WITH A FEDERAL EMISSION SYSTEM (SALES CODE NAA) MUST HAVE THEIR PCM REPROGRAMMED. IF THE SOFTWARE LEVEL IS AT OR HIGHER THAN THOSE IN THE OVERVIEW ABOVE, OR IF THE GRAND CHEROKEE HAS A CALIFORNIA EMISSIONS SYSTEM (SALES CODE NAE), REPROGRAMMING IS NOT NECESSARY. DIAGNOSIS PROCEDURES: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRBIII(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 performing this repair. If no DTC's are present, and the above symptom has been experienced, perform the Repair Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts > Page 3253 Procedure. NOTE: **IF OTHER PERFORMANCE ISSUES REMAIN AFTER THE REPAIR PROCEDURE HAS BEEN PERFORMED THEY DO NOT RELATE TO THIS BULLETIN. REFER TO THE PROPER SERVICE OR DIAGNOSTIC PROCEDURES MANUAL(S) FOR FURTHER ASSISTANCE.** PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD **2093 OR HIGHER AND DRB III(R) VERSION 52.3 WILL BE IN THE DEALERSHIPS ON OCTOBER 15, 2001.)** REPAIR PROCEDURE: 1. Log onto the MDS2 (Mopar Diagnostic System). 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III(R), MDS2, AND VEHICLE ESTABLISH COMMUNICATION. 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. 3. Push the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) 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. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. 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, 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 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts > Page 3254 7. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 8. 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > Page 3255 Transmission Control Module: Locations Fig. 13 Transmission Control Module Location The Transmission Control Module (TCM) is located in the engine compartment on the right (passenger) side and is mounted to the radiator core support. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions Transmission Control Module: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3258 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3259 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3260 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3261 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3262 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3263 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3264 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3265 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3266 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3267 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3268 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3269 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3270 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3271 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3272 Transmission Control Module: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3273 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3274 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3275 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3276 Transmission Control Module: Connector Views Transmission Control Module Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3277 Transmission Control Module Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3278 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 3279 Transmission Control Module: Description and Operation Fig. 13 Transmission Control Module Location The Transmission Control Module (TCM) is located in the engine compartment on the right (passenger) side and is mounted to the radiator core support (Fig. 13). The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hardwired to, and used specifically by the TCM. Indirect inputs originate from other components/modules, and are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - DRB Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 3280 - Transmission Temperature (to PCM) - PRNDL Position (to BCM) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with DRB scan tool) NOTE: If the TCM has been replaced, the "Quick Learn Procedure" must be performed. (Refer to ELECTRONIC CONTROL MODULES/ TRANSMISSION CONTROL MODULE - STANDARD PROCEDURE) Battery Feed A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain adaptive learn values in the TCM's RAM (Random Access Memory). When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. Clutch Volume Indexes (CVI) An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. Fig. 14 Example Of CVI Calculation By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur (Fig. 14). Gear ratios can be determined by using the DRB Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 3281 The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Clutch Volumes Certain mechanical problems within the input clutch assembly (broken return springs, out of position snap rings, excessive clutch pack clearance, improper assembly, etc.) can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following chart identifies the appropriate clutch volumes and when they are monitored/updated: Shift Schedules As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 3282 Driving Conditions As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 3283 Transmission Control Module: Service and Repair STANDARD PROCEDURES The quick learn procedure requires the use of the DRB scan tool. This program allows the electronic transmission system to recalibrate itself. This will provide the proper transmission operation. The quick learn procedure should be performed if any of the following procedures are performed: Transmission Assembly Replacement - Transmission Control Module Replacement - Solenoid Pack Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees. - The shift lever position must stay in PARK until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the DRB III indicates the procedure is complete - The calculated oil temperature must be above 60 ° and below 200 ° Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Transmission Control System Relay: Locations Power Distribution Center Transmission Control Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3287 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3288 Transmission Control System Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3289 Transmission Control Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3290 Transmission Control System Relay: Description and Operation DESCRIPTION The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. OPERATION When the relay is "off," no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Recalls for Control Module: > NHTSA01V077000 > Mar > 01 > Recall 01V077000: Transfer Case Control Module Problem Control Module: Recalls Recall 01V077000: Transfer Case Control Module Problem Vehicle Description: Light duty trucks and sport utility vehicles equipped with 4-wheel drive. The electric shift transfer case may not fully engage into gear when the operator moves the transfer case selector switch. This could cause the transfer case to end up in the neutral position unexpectedly and allow the vehicle to roll away if the parking brake is not applied. Dealers will reprogram the transfer case control module. Owner notification began April 9, 2001. 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 DaimlerChrysler at 1-800-853-1403. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > NHTSA01V077000 > Mar > 01 > Recall 01V077000: Transfer Case Control Module Problem Control Module: All Technical Service Bulletins Recall 01V077000: Transfer Case Control Module Problem Vehicle Description: Light duty trucks and sport utility vehicles equipped with 4-wheel drive. The electric shift transfer case may not fully engage into gear when the operator moves the transfer case selector switch. This could cause the transfer case to end up in the neutral position unexpectedly and allow the vehicle to roll away if the parking brake is not applied. Dealers will reprogram the transfer case control module. Owner notification began April 9, 2001. 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 DaimlerChrysler at 1-800-853-1403. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Service and Repair Fluid Pressure Sensor/Switch: Service and Repair LINE PRESSURE (LP) SENSOR REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pressure sensor (Fig. 81). 4. Remove the bolt holding the line pressure sensor to the transmission case. 5. Remove the line pressure sensor from the transmission case. INSTALLATION 1. Install the line pressure sensor into the transmission case. 2. Install the bolt to hold the line pressure sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 in. lbs.). 3. Install the wiring connector onto the line pressure sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3313 Overdrive Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3314 Overdrive Switch: Description and Operation DESCRIPTION The overdrive OFF (control) switch is located in the shift lever arm (Fig. 95). The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function. OPERATION At key-on, overdrive operation is allowed. Pressing the switch once causes the overdrive OFF mode to be entered and the overdrive OFF switch lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the overdrive lamp to be turned off. The overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the control switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4 upshift. The control switch indicator light illuminates only when the overdrive switch is turned to the OFF position, or when illuminated by the transmission control module. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3315 Overdrive Switch: Service and Repair REMOVAL 1. Using a plastic trim tool, remove the overdrive off switch retainer from the shift lever (Fig. 96). 2. Pull the switch outwards to release it from the connector in the lever (Fig. 97) INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector out of the lever just enough to grasp it. CAUTION: Be careful not to bend the pins on the overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3316 2. Install the overdrive off switch into the connector (Fig. 98) 3. Push the overdrive off switch and wiring into the shift lever. 4. Install the overdrive off switch retainer onto the shift lever. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Transmission Position Switch/Sensor: Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3323 Transmission Position Switch/Sensor: Description and Operation DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has six switch contacts that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. - Supply ground to the TCM for backup lamp control in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Specifications > 42RE (A-500) 4 Speed Transmission Speed Sensor: Specifications Sensor, trans speed 20 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Specifications > 42RE (A-500) 4 Speed > Page 3328 Transmission Speed Sensor: Specifications Bolt, input speed sensor 105 in.lb Bolt, output speed sensor 105 in.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Specifications > 42RE (A-500) 4 Speed > Page 3329 Transmission Speed Sensor: Specifications Sensor, trans speed 20 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Specifications > Page 3330 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Diagrams > Input Speed Sensor Input Speed Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Diagrams > Input Speed Sensor > Page 3333 Output Speed Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Input Speed Sensor Transmission Speed Sensor: Description and Operation Input Speed Sensor DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Input Speed Sensor > Page 3336 Transmission Speed Sensor: Description and Operation Output Speed Sensor OUTPUT SPEED SENSOR DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Service and Repair > Input Speed Sensor Transmission Speed Sensor: Service and Repair Input Speed Sensor REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (Fig. 80). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor from the transmission case. INSTALLATION 1. Install the input speed sensor into the transmission case. 2. Install the bolt to hold the input speed sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the input speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Service and Repair > Input Speed Sensor > Page 3339 Transmission Speed Sensor: Service and Repair Output Speed Sensor OUTPUT SPEED SENSOR REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor (Fig. 94). 4. Remove the bolt holding the output speed sensor to the transmission case. 5. Remove the output speed sensor from the transmission case. INSTALLATION 1. Install the output speed sensor into the transmission case. 2. Install the bolt to hold the output speed sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the output speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3343 Transmission Temperature Sensor/Switch: Description and Operation DESCRIPTION The transmission temperature sensor is a thermistor that is integral to the Transmission Range Sensor (TRS). OPERATION The transmission temperature sensor is used by the TCM to sense the temperature of the fluid in the sump. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. Calculated Temperature A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Overdrive Switch, M/T > Component Information > Diagrams Overdrive Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-021-01A > Sep > 01 > Engine - Spark Knock/Hesitation/Sag PROM - Programmable Read Only Memory: Customer Interest Engine - Spark Knock/Hesitation/Sag NUMBER: 18-021-01 REV. A GROUP: Vehicle Performance DATE: September 17, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-021-01, DATED SEPTEMBER 17, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** WHICH INCLUDE CHANGES TO THE LABOR OPERATION NUMBER. SUBJECT: 4.7L Engine Performance Enhancements OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (WJ O1CAL15C, DN O1CAL 14D). MODELS: 2001 DN Durango 2001 WJ Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 4.7L (EVA) ENGINE AND CALIBRATION LEVEL PRIOR TO (LESS OR LOWER THAN) THOSE LISTED IN THE OVERVIEW ABOVE. SYMPTOM/CONDITION: Some vehicles may exhibit one or more of the following engine performance conditions. 1. Part throttle or wide-open throttle spark knock. 2. Sag or hesitation after a cold engine start up. DIAGNOSIS: 1. Using the Diagnostic Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures, verify all engine/transmission systems are functioning as designed. If other Diagnostic Trouble Codes (DTC) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the condition(s) above is seen perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-021-01A > Sep > 01 > Engine - Spark Knock/Hesitation/Sag > Page 3356 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 2091 OR HIGHER (CD 2091 ARRIVES IN DEALERSHIPS ON SEPTEMBER 17, 2001). REPAIR PROCEDURE: 1. Log onto the MDS2 (Mopar Diagnostic System). 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III(R), MDS2, AND VEHICLE ESTABLISH COMMUNICATION. 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. 3. Push the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) 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. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. 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, 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 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. 7. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-021-01A > Sep > 01 > Engine - Spark Knock/Hesitation/Sag > Page 3357 8. 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-011-01 > May > 01 > PCM - MIL ON, DTC's P0071 or P0135 or P0141 Set PROM - Programmable Read Only Memory: Customer Interest PCM - MIL ON, DTC's P0071 or P0135 or P0141 Set NUMBER: 18-011-01 GROUP: Vehicle Performance DATE: May 11, 2001 SUBJECT: MIL Illumination (P0071 Battery Temperature Sensor Performance, or P0135 or P0141 Oxygen Sensor Heater Performance) OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration level 01Cal14b.) MODELS: 2001 (AB) Ram Van/Wagon 2001 (AN) Dakota 2001 (BR/BE) Ram Truck 2001 (DN) Durango 2001 (SR) Viper NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A GASOLINE ENGINE. CALIBRATION LEVEL MUST BE PRIOR TO (LESS OR LOWER THAN) 2001 CAL14B. CAREFULLY READ THE NOTES BELOW FOR OTHER CONDITIONS RELATED TO THE "OXYGEN SENSOR HEATER PERFORMANCE" CONDITION. SYMPTOM/CONDITION: Customer will experience MIL illumination. DIAGNOSIS PROCEDURES: 1. Using the Diagnostic Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures, verify all engine/transmission systems are functioning as designed. If other DTC's are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. It the condition seen is a MIL "on" and either Diagnostic Trouble Code (DTC) for "Oxygen Sensor Heater Performance" (P0135 OR P0141) is present, and the vehicle is equipped with a single upstream oxygen sensor system (see table below) perform the repair procedure. If the vehicle is not included in the table below, perform the repair procedure and follow normal diagnostic procedures to correct the "Oxygen Sensor Heater Performance" condition. 3. If the MIL light is "on", and the vehicle calibration level is already at 2001 CAL14B or higher, and the DTC's for "Oxygen Sensor Heater Performance" (P0135 OR P0141) are present, follow normal diagnostic procedures to correct the problem. PARTS REQUIRED: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-011-01 > May > 01 > PCM - MIL ON, DTC's P0071 or P0135 or P0141 Set > Page 3362 EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRBIII(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR, WHEN USING THE MDS2 AND THE DRBIII(R) THE SYSTEM MUST BE OPERATING AT CIS CD 2083 OR HIGHER (2083 ARRIVES IN DEALERSHIPS ON MAY 28, 2001). REPAIR PROCEDURE: 1. Log onto the MDS2 (Mopar Diagnostic System). 2. Connect the MDS2 and DRBIII(R) to the vehicle and switch the ignition key to "ON". NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRBIII(R), MDS2, AND VEHICLE ESTABLISH COMMUNICATION. THE "CANNOT READ VIN FROM DRBIII(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. 3. Push the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) 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. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. The MDS2 and DRBIII(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, 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 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-011-01 > May > 01 > PCM - MIL ON, DTC's P0071 or P0135 or P0141 Set > Page 3363 7. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 8. 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 08-006-01 > Mar > 01 > Overhead Console Display Inaccurate MPG Reading PROM - Programmable Read Only Memory: Customer Interest Overhead Console Display Inaccurate MPG Reading NUMBER: 08-006-01 GROUP: Electrical DATE: Mar. 23, 2001 SUBJECT: Inaccurate Miles Per Gallon/Distance To Empty Reading From Overhead Console OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration level 01Cal14) MODELS: 2001 (AN) Dakota 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 4.7L ENGINE. SYMPTOM/CONDITION: The vehicle's overhead console may display a Miles Per Gallon (MPG) that is approximately two MPG higher than what the vehicle actually is getting. Additionally, one of the inputs for the Distance To Empty (DTE) reading is taken from the MPG reading which may cause the DTE reading to be inaccurate. DIAGNOSIS/REPAIR PROCEDURES: Due to the nature of this issue, perform the Repair Procedure on any subject model vehicle in which the customer complains that the vehicle is getting approximately two miles per gallon less than displayed on the overhead console. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRBIII(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR, WHEN USING THE MDS2 AND THE DRBIII(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2077 OR HIGHER. REPAIR PROCEDURE: 1. Reprogram the PCM using the MDS2 (Mopar Diagnostic System) and the DRB III(R) (Scan Tool). NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, 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 WITH A MODULE. 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 ERASED. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 08-006-01 > Mar > 01 > Overhead Console Display Inaccurate MPG Reading > Page 3368 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 PCM 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-006-01A > Mar > 01 > PCM - Engine Spark Knock Under Load PROM - Programmable Read Only Memory: Customer Interest PCM - Engine Spark Knock Under Load NUMBER: 18-006-01 REV A GROUP: Vehicle Performance DATE: Mar. 02, 2001 THIS BULLETIN SUPERCEDES TECHNICAL SERVICE BULLETIN 18-006-01, DATED FEB. 23, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THIS LATEST REVISION INCLUDES ADDITIONAL EMISSIONS PACKAGES. SUBJECT: 2001 M.Y. Engine Spark Knock OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration level 01Cal1ED, 01Cal13, or 01Cal14) MODELS: 2001 (AB) Ram Van 2001 (BR/BE) Ram Truck 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES WITH PCM SOFTWARE THAT IS EARLIER (LESS OR LOWER) THAN THE CALIBRATIONS LISTED IN THE TABLE SHOWN. REFER TO THE TWO TABLES FOR SPECIFIC APPLICATIONS AND EXCLUSIONS. NOTE: THE FOLLOWING EMISSION PACKAGES ARE NOT APPROVED AND ARE EXCLUDED FROM THIS BULLETIN. THE PCM CALIBRATION OF ANY EXCLUDED VEHICLE IS NOT TO BE REPROGRAMMED FOR A SPARK KNOCK COMPLAINT. BEFORE ATTEMPTING A REPROGRAMMING SESSION INSPECT THE TYPE VEHICLE AND ENGINE FOR POSSIBLE EXCLUSION. SEE TABLE AS SHOWN. SYMPTOM/CONDITION: Some vehicle engines may exhibit a light-to-moderate spark knock condition during acceleration (under load). DIAGNOSIS: 1. Verify that the above tables and the following NOTE(S) have been reviewed and understood. 2. Verify the calibration level of the PCM. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-006-01A > Mar > 01 > PCM - Engine Spark Knock Under Load > Page 3373 3. Verify that the engine coolant contains a quality antifreeze. The coolant mixture should consist of 44% to 68% antifreeze. 4. If the only condition seen is the light-to-moderate engine spark knock and the PCM calibration is earlier (less or lower) than the calibrations listed in the table above, then perform the Repair Procedure. NOTE: WHEN PULLING A HEAVY LOAD OR DRIVING A FULLY LOADED VEHICLE USE A PREMIUM UNLEADED FUEL TO HELP MINIMIZE SPARK KNOCK. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 SYSTEM MUST BE OPERATING AT THE RESPECTIVE CIS CD LEVEL AS LISTED ABOVE IN THE FIRST TABLE. REPAIR PROCEDURE: 1. Reprogram the PCM using the MDS2 (Mopar Diagnostic System) - and the DRB III(R) (Scan Tool). NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, 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 WITH A MODULE. 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 ERASED. 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 PCM and cover the label with the clear plastic overlay. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-006-01A > Mar > 01 > PCM - Engine Spark Knock Under Load > Page 3374 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3380 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3381 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3382 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3383 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3384 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3385 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3386 ^ 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3387 ^ 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3388 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3389 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3390 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3391 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3392 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3393 ^ 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3394 ^ 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3395 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3396 ^ 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3397 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3398 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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: > 18-021-01A > Sep > 01 > Engine - Spark Knock/Hesitation/Sag PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine - Spark Knock/Hesitation/Sag NUMBER: 18-021-01 REV. A GROUP: Vehicle Performance DATE: September 17, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-021-01, DATED SEPTEMBER 17, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** WHICH INCLUDE CHANGES TO THE LABOR OPERATION NUMBER. SUBJECT: 4.7L Engine Performance Enhancements OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (WJ O1CAL15C, DN O1CAL 14D). MODELS: 2001 DN Durango 2001 WJ Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 4.7L (EVA) ENGINE AND CALIBRATION LEVEL PRIOR TO (LESS OR LOWER THAN) THOSE LISTED IN THE OVERVIEW ABOVE. SYMPTOM/CONDITION: Some vehicles may exhibit one or more of the following engine performance conditions. 1. Part throttle or wide-open throttle spark knock. 2. Sag or hesitation after a cold engine start up. DIAGNOSIS: 1. Using the Diagnostic Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures, verify all engine/transmission systems are functioning as designed. If other Diagnostic Trouble Codes (DTC) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the condition(s) above is seen perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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: > 18-021-01A > Sep > 01 > Engine - Spark Knock/Hesitation/Sag > Page 3403 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 2091 OR HIGHER (CD 2091 ARRIVES IN DEALERSHIPS ON SEPTEMBER 17, 2001). REPAIR PROCEDURE: 1. Log onto the MDS2 (Mopar Diagnostic System). 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III(R), MDS2, AND VEHICLE ESTABLISH COMMUNICATION. 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. 3. Push the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) 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. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. 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, 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 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. 7. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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: > 18-021-01A > Sep > 01 > Engine - Spark Knock/Hesitation/Sag > Page 3404 8. 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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: > 18-011-01 > May > 01 > PCM - MIL ON, DTC's P0071 or P0135 or P0141 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - MIL ON, DTC's P0071 or P0135 or P0141 Set NUMBER: 18-011-01 GROUP: Vehicle Performance DATE: May 11, 2001 SUBJECT: MIL Illumination (P0071 Battery Temperature Sensor Performance, or P0135 or P0141 Oxygen Sensor Heater Performance) OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration level 01Cal14b.) MODELS: 2001 (AB) Ram Van/Wagon 2001 (AN) Dakota 2001 (BR/BE) Ram Truck 2001 (DN) Durango 2001 (SR) Viper NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A GASOLINE ENGINE. CALIBRATION LEVEL MUST BE PRIOR TO (LESS OR LOWER THAN) 2001 CAL14B. CAREFULLY READ THE NOTES BELOW FOR OTHER CONDITIONS RELATED TO THE "OXYGEN SENSOR HEATER PERFORMANCE" CONDITION. SYMPTOM/CONDITION: Customer will experience MIL illumination. DIAGNOSIS PROCEDURES: 1. Using the Diagnostic Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures, verify all engine/transmission systems are functioning as designed. If other DTC's are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. It the condition seen is a MIL "on" and either Diagnostic Trouble Code (DTC) for "Oxygen Sensor Heater Performance" (P0135 OR P0141) is present, and the vehicle is equipped with a single upstream oxygen sensor system (see table below) perform the repair procedure. If the vehicle is not included in the table below, perform the repair procedure and follow normal diagnostic procedures to correct the "Oxygen Sensor Heater Performance" condition. 3. If the MIL light is "on", and the vehicle calibration level is already at 2001 CAL14B or higher, and the DTC's for "Oxygen Sensor Heater Performance" (P0135 OR P0141) are present, follow normal diagnostic procedures to correct the problem. PARTS REQUIRED: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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: > 18-011-01 > May > 01 > PCM - MIL ON, DTC's P0071 or P0135 or P0141 Set > Page 3409 EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRBIII(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR, WHEN USING THE MDS2 AND THE DRBIII(R) THE SYSTEM MUST BE OPERATING AT CIS CD 2083 OR HIGHER (2083 ARRIVES IN DEALERSHIPS ON MAY 28, 2001). REPAIR PROCEDURE: 1. Log onto the MDS2 (Mopar Diagnostic System). 2. Connect the MDS2 and DRBIII(R) to the vehicle and switch the ignition key to "ON". NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRBIII(R), MDS2, AND VEHICLE ESTABLISH COMMUNICATION. THE "CANNOT READ VIN FROM DRBIII(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. 3. Push the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) 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. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. The MDS2 and DRBIII(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, 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 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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: > 18-011-01 > May > 01 > PCM - MIL ON, DTC's P0071 or P0135 or P0141 Set > Page 3410 7. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 8. 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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: > 08-006-01 > Mar > 01 > Overhead Console Display - Inaccurate MPG Reading PROM - Programmable Read Only Memory: All Technical Service Bulletins Overhead Console Display - Inaccurate MPG Reading NUMBER: 08-006-01 GROUP: Electrical DATE: Mar. 23, 2001 SUBJECT: Inaccurate Miles Per Gallon/Distance To Empty Reading From Overhead Console OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration level 01Cal14) MODELS: 2001 (AN) Dakota 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 4.7L ENGINE. SYMPTOM/CONDITION: The vehicle's overhead console may display a Miles Per Gallon (MPG) that is approximately two MPG higher than what the vehicle actually is getting. Additionally, one of the inputs for the Distance To Empty (DTE) reading is taken from the MPG reading which may cause the DTE reading to be inaccurate. DIAGNOSIS/REPAIR PROCEDURES: Due to the nature of this issue, perform the Repair Procedure on any subject model vehicle in which the customer complains that the vehicle is getting approximately two miles per gallon less than displayed on the overhead console. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRBIII(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR, WHEN USING THE MDS2 AND THE DRBIII(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2077 OR HIGHER. REPAIR PROCEDURE: 1. Reprogram the PCM using the MDS2 (Mopar Diagnostic System) and the DRB III(R) (Scan Tool). NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, 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 WITH A MODULE. 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 ERASED. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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: > 08-006-01 > Mar > 01 > Overhead Console Display - Inaccurate MPG Reading > Page 3415 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 PCM 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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: > 18-006-01A > Mar > 01 > PCM - Engine Spark Knock Under Load PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - Engine Spark Knock Under Load NUMBER: 18-006-01 REV A GROUP: Vehicle Performance DATE: Mar. 02, 2001 THIS BULLETIN SUPERCEDES TECHNICAL SERVICE BULLETIN 18-006-01, DATED FEB. 23, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THIS LATEST REVISION INCLUDES ADDITIONAL EMISSIONS PACKAGES. SUBJECT: 2001 M.Y. Engine Spark Knock OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration level 01Cal1ED, 01Cal13, or 01Cal14) MODELS: 2001 (AB) Ram Van 2001 (BR/BE) Ram Truck 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES WITH PCM SOFTWARE THAT IS EARLIER (LESS OR LOWER) THAN THE CALIBRATIONS LISTED IN THE TABLE SHOWN. REFER TO THE TWO TABLES FOR SPECIFIC APPLICATIONS AND EXCLUSIONS. NOTE: THE FOLLOWING EMISSION PACKAGES ARE NOT APPROVED AND ARE EXCLUDED FROM THIS BULLETIN. THE PCM CALIBRATION OF ANY EXCLUDED VEHICLE IS NOT TO BE REPROGRAMMED FOR A SPARK KNOCK COMPLAINT. BEFORE ATTEMPTING A REPROGRAMMING SESSION INSPECT THE TYPE VEHICLE AND ENGINE FOR POSSIBLE EXCLUSION. SEE TABLE AS SHOWN. SYMPTOM/CONDITION: Some vehicle engines may exhibit a light-to-moderate spark knock condition during acceleration (under load). DIAGNOSIS: 1. Verify that the above tables and the following NOTE(S) have been reviewed and understood. 2. Verify the calibration level of the PCM. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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: > 18-006-01A > Mar > 01 > PCM - Engine Spark Knock Under Load > Page 3420 3. Verify that the engine coolant contains a quality antifreeze. The coolant mixture should consist of 44% to 68% antifreeze. 4. If the only condition seen is the light-to-moderate engine spark knock and the PCM calibration is earlier (less or lower) than the calibrations listed in the table above, then perform the Repair Procedure. NOTE: WHEN PULLING A HEAVY LOAD OR DRIVING A FULLY LOADED VEHICLE USE A PREMIUM UNLEADED FUEL TO HELP MINIMIZE SPARK KNOCK. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 SYSTEM MUST BE OPERATING AT THE RESPECTIVE CIS CD LEVEL AS LISTED ABOVE IN THE FIRST TABLE. REPAIR PROCEDURE: 1. Reprogram the PCM using the MDS2 (Mopar Diagnostic System) - and the DRB III(R) (Scan Tool). NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, 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 WITH A MODULE. 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 ERASED. 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 PCM and cover the label with the clear plastic overlay. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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: > 18-006-01A > Mar > 01 > PCM - Engine Spark Knock Under Load > Page 3421 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3427 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3428 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3429 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3430 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3431 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3432 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3433 ^ 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3434 ^ 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3435 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3436 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3437 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3438 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3439 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3440 ^ 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3441 ^ 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3442 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3443 ^ 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3444 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 3445 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair Shift Solenoid: Service and Repair REMOVAL 1. Remove the valve body from the transmission (Fig. 116). 2. Remove the screws holding the transmission solenoid/TRS assembly onto the valve body (Fig. 117). 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the screws to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 5.7 Nm (50 inch lbs.). 5. Tighten the remainder of the solenoid assembly screws to 5.7 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance Torque Converter Clutch Solenoid: Customer Interest MIL ON - TCC/OD Solenoid Performance NUMBER: 21-11-00 GROUP: Transmissions EFFECTIVE DATE: October 02, 2000 SUBJECT: 46RE Transmission MIL Due To DTC P1740 - TCC or OD Solenoid Performance OVERVIEW: This bulletin involves the replacement of the transmission pressure boost valve cover plate. MODELS: 2000 - 2001 (AB) Ram Van 2000 - 2001 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 - 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 46RE TRANSMISSION BUILT BEFORE AUGUST 01, 2000 (MDH O8O1XX). SYMPTOM/CONDITION: The customer may complain of a Malfunction Indicator Lamp (MIL) illumination. Upon further analysis, it is determined that the MIL is caused by Diagnostic Trouble Code (DTC) P1740 - Torque Converter Clutch (TCC) or Overdrive Solenoid Performance. Other than the MIL, the customer may not notice any other condition with the transmission. This condition may be caused by an intermittent and momentary TCC disengagement condition. The transmission valve body pressure boost valve cover plate has been revised with a larger size orifice hole to address this condition. DIAGNOSIS: 1. Warm the transmission to normal operating temperatures. 2. Using the DRB III(R), perform a torque converter clutch (TCC) stall test. The stall test has been revised so that the TCC remains engaged for a period of four (4) seconds. NOTE: THE DRB III(R) MUST BE OPERATING AT RELEASE LEVEL 50.4 MDS2 SYSTEM CIS CD2067 OR HIGHER (AVAILABLE THE WEEK OF OCTOBER 2, 2000) IN ORDER TO PERFORM THE REVISED TORQUE CONVERTER CLUTCH STALL TEST. DO NOT USE EARLIER VERSION STALL TEST TO DETERMINE CONDITION OF THE TORQUE CONVERTER CLUTCH. 3. If the engine stalls as a result of the TCC stall test, then perform the Repair Procedure. 4. If the engine does not stall, as a result of the TCC stall test, then further diagnosis is required. The technician may want to consider the following components during their additional diagnosis: a cut or worn input shaft seals, a missing pump lock-up circuit check ball, or worn converter hub, input shaft, reaction shaft, and pump rotor. PARTS REQUIRED: REPAIR PROCEDURE: 1. Clean the pressure boost valve cover plate to remove any dirt or rust inhibitor prior to installation. The revised cover plate will have a 1.75 mm (0.069 inch) orifice hole versus a 1.22 mm (0.048 inch) orifice hole in the original plate. Make sure it is clean. 2. Using the appropriate Service Manual, Group 21 - Transmissions and Transfer Case, replace the transmission pressure boost valve cover plate p/n Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance > Page 3463 04617012. 3. Verify fluid level after warming up the transmission and cycling the shift lever several times. 4. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance Torque Converter Clutch Solenoid: All Technical Service Bulletins MIL ON - TCC/OD Solenoid Performance NUMBER: 21-11-00 GROUP: Transmissions EFFECTIVE DATE: October 02, 2000 SUBJECT: 46RE Transmission MIL Due To DTC P1740 - TCC or OD Solenoid Performance OVERVIEW: This bulletin involves the replacement of the transmission pressure boost valve cover plate. MODELS: 2000 - 2001 (AB) Ram Van 2000 - 2001 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 - 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 46RE TRANSMISSION BUILT BEFORE AUGUST 01, 2000 (MDH O8O1XX). SYMPTOM/CONDITION: The customer may complain of a Malfunction Indicator Lamp (MIL) illumination. Upon further analysis, it is determined that the MIL is caused by Diagnostic Trouble Code (DTC) P1740 - Torque Converter Clutch (TCC) or Overdrive Solenoid Performance. Other than the MIL, the customer may not notice any other condition with the transmission. This condition may be caused by an intermittent and momentary TCC disengagement condition. The transmission valve body pressure boost valve cover plate has been revised with a larger size orifice hole to address this condition. DIAGNOSIS: 1. Warm the transmission to normal operating temperatures. 2. Using the DRB III(R), perform a torque converter clutch (TCC) stall test. The stall test has been revised so that the TCC remains engaged for a period of four (4) seconds. NOTE: THE DRB III(R) MUST BE OPERATING AT RELEASE LEVEL 50.4 MDS2 SYSTEM CIS CD2067 OR HIGHER (AVAILABLE THE WEEK OF OCTOBER 2, 2000) IN ORDER TO PERFORM THE REVISED TORQUE CONVERTER CLUTCH STALL TEST. DO NOT USE EARLIER VERSION STALL TEST TO DETERMINE CONDITION OF THE TORQUE CONVERTER CLUTCH. 3. If the engine stalls as a result of the TCC stall test, then perform the Repair Procedure. 4. If the engine does not stall, as a result of the TCC stall test, then further diagnosis is required. The technician may want to consider the following components during their additional diagnosis: a cut or worn input shaft seals, a missing pump lock-up circuit check ball, or worn converter hub, input shaft, reaction shaft, and pump rotor. PARTS REQUIRED: REPAIR PROCEDURE: 1. Clean the pressure boost valve cover plate to remove any dirt or rust inhibitor prior to installation. The revised cover plate will have a 1.75 mm (0.069 inch) orifice hole versus a 1.22 mm (0.048 inch) orifice hole in the original plate. Make sure it is clean. 2. Using the appropriate Service Manual, Group 21 - Transmissions and Transfer Case, replace the transmission pressure boost valve cover plate p/n Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance > Page 3469 04617012. 3. Verify fluid level after warming up the transmission and cycling the shift lever several times. 4. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Technical Service Bulletins > Page 3470 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Overdrive Solenoid, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Service and Repair Shift Solenoid: Service and Repair REMOVAL 1. Remove the valve body from the transmission (Fig. 116). 2. Remove the screws holding the transmission solenoid/TRS assembly onto the valve body (Fig. 117). 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the screws to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 5.7 Nm (50 inch lbs.). 5. Tighten the remainder of the solenoid assembly screws to 5.7 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance Torque Converter Clutch Solenoid: Customer Interest MIL ON - TCC/OD Solenoid Performance NUMBER: 21-11-00 GROUP: Transmissions EFFECTIVE DATE: October 02, 2000 SUBJECT: 46RE Transmission MIL Due To DTC P1740 - TCC or OD Solenoid Performance OVERVIEW: This bulletin involves the replacement of the transmission pressure boost valve cover plate. MODELS: 2000 - 2001 (AB) Ram Van 2000 - 2001 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 - 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 46RE TRANSMISSION BUILT BEFORE AUGUST 01, 2000 (MDH O8O1XX). SYMPTOM/CONDITION: The customer may complain of a Malfunction Indicator Lamp (MIL) illumination. Upon further analysis, it is determined that the MIL is caused by Diagnostic Trouble Code (DTC) P1740 - Torque Converter Clutch (TCC) or Overdrive Solenoid Performance. Other than the MIL, the customer may not notice any other condition with the transmission. This condition may be caused by an intermittent and momentary TCC disengagement condition. The transmission valve body pressure boost valve cover plate has been revised with a larger size orifice hole to address this condition. DIAGNOSIS: 1. Warm the transmission to normal operating temperatures. 2. Using the DRB III(R), perform a torque converter clutch (TCC) stall test. The stall test has been revised so that the TCC remains engaged for a period of four (4) seconds. NOTE: THE DRB III(R) MUST BE OPERATING AT RELEASE LEVEL 50.4 MDS2 SYSTEM CIS CD2067 OR HIGHER (AVAILABLE THE WEEK OF OCTOBER 2, 2000) IN ORDER TO PERFORM THE REVISED TORQUE CONVERTER CLUTCH STALL TEST. DO NOT USE EARLIER VERSION STALL TEST TO DETERMINE CONDITION OF THE TORQUE CONVERTER CLUTCH. 3. If the engine stalls as a result of the TCC stall test, then perform the Repair Procedure. 4. If the engine does not stall, as a result of the TCC stall test, then further diagnosis is required. The technician may want to consider the following components during their additional diagnosis: a cut or worn input shaft seals, a missing pump lock-up circuit check ball, or worn converter hub, input shaft, reaction shaft, and pump rotor. PARTS REQUIRED: REPAIR PROCEDURE: 1. Clean the pressure boost valve cover plate to remove any dirt or rust inhibitor prior to installation. The revised cover plate will have a 1.75 mm (0.069 inch) orifice hole versus a 1.22 mm (0.048 inch) orifice hole in the original plate. Make sure it is clean. 2. Using the appropriate Service Manual, Group 21 - Transmissions and Transfer Case, replace the transmission pressure boost valve cover plate p/n Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance > Page 3487 04617012. 3. Verify fluid level after warming up the transmission and cycling the shift lever several times. 4. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance Torque Converter Clutch Solenoid: All Technical Service Bulletins MIL ON - TCC/OD Solenoid Performance NUMBER: 21-11-00 GROUP: Transmissions EFFECTIVE DATE: October 02, 2000 SUBJECT: 46RE Transmission MIL Due To DTC P1740 - TCC or OD Solenoid Performance OVERVIEW: This bulletin involves the replacement of the transmission pressure boost valve cover plate. MODELS: 2000 - 2001 (AB) Ram Van 2000 - 2001 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 - 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 46RE TRANSMISSION BUILT BEFORE AUGUST 01, 2000 (MDH O8O1XX). SYMPTOM/CONDITION: The customer may complain of a Malfunction Indicator Lamp (MIL) illumination. Upon further analysis, it is determined that the MIL is caused by Diagnostic Trouble Code (DTC) P1740 - Torque Converter Clutch (TCC) or Overdrive Solenoid Performance. Other than the MIL, the customer may not notice any other condition with the transmission. This condition may be caused by an intermittent and momentary TCC disengagement condition. The transmission valve body pressure boost valve cover plate has been revised with a larger size orifice hole to address this condition. DIAGNOSIS: 1. Warm the transmission to normal operating temperatures. 2. Using the DRB III(R), perform a torque converter clutch (TCC) stall test. The stall test has been revised so that the TCC remains engaged for a period of four (4) seconds. NOTE: THE DRB III(R) MUST BE OPERATING AT RELEASE LEVEL 50.4 MDS2 SYSTEM CIS CD2067 OR HIGHER (AVAILABLE THE WEEK OF OCTOBER 2, 2000) IN ORDER TO PERFORM THE REVISED TORQUE CONVERTER CLUTCH STALL TEST. DO NOT USE EARLIER VERSION STALL TEST TO DETERMINE CONDITION OF THE TORQUE CONVERTER CLUTCH. 3. If the engine stalls as a result of the TCC stall test, then perform the Repair Procedure. 4. If the engine does not stall, as a result of the TCC stall test, then further diagnosis is required. The technician may want to consider the following components during their additional diagnosis: a cut or worn input shaft seals, a missing pump lock-up circuit check ball, or worn converter hub, input shaft, reaction shaft, and pump rotor. PARTS REQUIRED: REPAIR PROCEDURE: 1. Clean the pressure boost valve cover plate to remove any dirt or rust inhibitor prior to installation. The revised cover plate will have a 1.75 mm (0.069 inch) orifice hole versus a 1.22 mm (0.048 inch) orifice hole in the original plate. Make sure it is clean. 2. Using the appropriate Service Manual, Group 21 - Transmissions and Transfer Case, replace the transmission pressure boost valve cover plate p/n Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance > Page 3493 04617012. 3. Verify fluid level after warming up the transmission and cycling the shift lever several times. 4. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Page 3494 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation Accumulator: Description and Operation DESCRIPTION The accumulator (Fig. 58) is a hydraulic device that has the sole purpose of cushioning the application of a band or clutch. The accumulator consists of a dual-land piston and a spring located in a bore in the transmission case. The 3-4 accumulator is located in a housing attached to the side of the valve body (Fig. 59). OPERATION Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > Page 3498 Both the accumulator and the 3-4 accumulator function the same. Line pressure is directed to the small end of the piston when the transmission is placed into a DRIVE position (Fig. 60), bottoming it against the accumulator plate. When the 1-2 upshift occurs (Fig. 61), line pressure is directed to the large end of the piston and then to the kickdown servo. As the line pressure reaches the accumulator, the combination of spring pressure and line pressure forces the piston away from the accumulator plate. This causes a balanced pressure situation, which results in a cushioned band application. After the kickdown servo has become immovable, line pressure will finish pushing the accumulator up into its bore. When the large end of the accumulator piston is seated in its bore, the band or clutch is fully applied. NOTE: The accumulator is shown in the inverted position for illustrative purposes. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > Page 3499 Accumulator: Testing and Inspection INSPECTION Inspect the accumulator piston and seal rings (Fig. 62). Replace the seal rings if worn or cut. Replace the piston if chipped or cracked. Check condition of the accumulator inner and outer springs (Fig. 62). Replace the springs if the coils are cracked, distorted or collapsed. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed Band: Description and Operation 42RE (A-500) 4 Speed DESCRIPTION KICKDOWN (FRONT) BAND The kickdown, or "front", band (Fig. 63) holds the common sun gear of the planetary gear sets. The front (kickdown) band is made of steel, and faced on its inner circumference with a friction-type lining. One end of the band is anchored to the transmission case, and the other is acted on with a pushing force by a servo piston. The front band is a single-wrap design (the band does not completely encompass/ wrap the drum that it holds). LOW/REVERSE (REAR) BAND The low/reverse band, or "rear", band (Fig. 64) is similar in appearance and operation to the front band. The rear band is slightly different in that it does not use a link bar, but is acted directly on by the apply lever. This is referred to as a double-wrap band design (the drum is completely encompassed/ wrapped by the band). The double-wrap band provides a greater holding power in comparison to the single-wrap design. OPERATION KICKDOWN (FRONT) BAND The kickdown band holds the common sun gear of the planetary gear sets by applying and holding the front clutch retainer, which is splined to the sun gear driving shell, and in turn splined directly to the sun gear. The application of the band by the servo is typically done by an apply lever and link bar. LOW/REVERSE (REAR) BAND The rear band holds the rear planet carrier stationary by being mounted around and applied to the low/reverse drum. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3504 Band: Description and Operation 46RE (A-518) 4 Speed DESCRIPTION KICKDOWN (FRONT) BAND The kickdown, or "front", band (Fig. 70) holds the common sun gear of the planetary gear sets. The front (kickdown) band is made of steel, and faced on its inner circumference with a friction-type lining. One end of the band is anchored to the transmission case, and the other is acted on with a pushing force by a servo piston. The front band is a single-wrap design (the band does not completely encompass/ wrap the drum that it holds). LOW/REVERSE (REAR) BAND The low/reverse band, or "rear", band (Fig. 71) is similar in appearance and operation to the front band. The rear band is also a single-wrap design ( the band does not completely encompass/wrap the drum that it holds). OPERATION KICKDOWN (FRONT) BAND The kickdown band holds the common sun gear of the planetary gear sets by applying and holding the front clutch retainer, which is splined to the sun gear driving shell, and in turn splined directly to the sun gear, The application of the band by the servo is typically done by an apply lever and link bar. LOW/REVERSE (REAR) BAND The rear band holds the rear planet carrier stationary by being mounted around and applied to the low/reverse drum. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications Clutch: Specifications 2C Clutch Pack Clearance 0.021 - 0.050 in 4C Clutch Pack Clearance 0.032 - 0.053 in UR Clutch Pack Clearance 0.045 - 0.075 in OD Clutch Pack Clearance 0.040 - 0.065 in UD Clutch Pack Clearance 0.030 - 0.063 in Reverse Clutch Pack Clearance 0.032 - 0.049 in Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Holding Clutch Clutch: Description and Operation Holding Clutch HOLDING CLUTCHES DESCRIPTION Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Holding Clutch > Page 3510 Three hydraulically applied multi-disc clutches are used to hold some planetary geartrain components stationary while the input clutches drive others. The 2C, 4C, and Low/Reverse clutches are considered holding clutches. The 2C and 4C clutches are located in the 4C retainer/bulkhead (Fig. 64), while the Low/ Reverse clutch is located at the rear of the transmission case (Fig. 65). OPERATION 2C CLUTCH The 2C clutch is hydraulically applied in second gear by pressurized fluid against the 2C piston. When the 2C clutch is applied, the reverse sun gear assembly is held or grounded to the transmission case by holding the reaction planetary carrier. 4C CLUTCH The 4C clutch is hydraulically applied in second prime and fourth gear by pressurized fluid against the 4C clutch piston. When the 4C clutch is applied, the reaction annulus gear is held or grounded to the transmission case. LOW/REVERSE CLUTCH The Low/Reverse clutch is hydraulically applied in park, reverse, neutral, and first gear, only at low speeds, by pressurized fluid against the Low/Reverse clutch piston. When the Low/Reverse clutch is applied, the input annulus assembly is held or grounded to the transmission case. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Holding Clutch > Page 3511 Clutch: Description and Operation Input Clutch DESCRIPTION Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Holding Clutch > Page 3512 Three hydraulically applied input clutches are used to drive planetary components. The underdrive, overdrive, and reverse clutches are considered input clutches and are contained within the input clutch assembly (Fig. 66) and (Fig. 67). The input clutch assembly also contains: Input shaft - Input hub - Clutch retainer - Underdrive piston - Overdrive/reverse piston - Overdrive hub - Underdrive hub OPERATION The three input clutches are responsible for driving different components of the planetary geartrain. UNDERDRIVE CLUTCH The underdrive clutch is hydraulically applied in first, second, second prime, and third (direct) gears by pressurized fluid against the underdrive piston. When the underdrive clutch is applied, the underdrive hub drives the input sun gear. OVERDRIVE CLUTCH The overdrive clutch is hydraulically applied in third (direct) and fourth gears by pressurized fluid against the overdrive/reverse piston. When the overdrive clutch is applied, the overdrive hub drives the reverse carrier/input annulus assembly. REVERSE CLUTCH The reverse clutch is hydraulically applied in reverse gear by pressurized fluid against the overdrive/reverse piston. When the reverse clutch is applied, the reaction annulus gear is driven. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Input Clutch Clutch: Service and Repair Input Clutch DISASSEMBLY 1. Remove the reverse reaction plate selective snap-ring from the input clutch retainer (Fig. 68). 2. Remove the reverse reaction plate from the input clutch retainer. 3. Remove the reverse hub and reverse clutch pack from the input clutch retainer. 4. Remove the number 4 bearing from the overdrive hub. 5. Remove the overdrive hub from the input clutch retainer (Fig. 68). 6. Remove the number 3 bearing from the underdrive hub. 7. Remove the OD/reverse reaction plate snap-ring from the input clutch retainer. 8. Remove the underdrive hub, overdrive clutch, and overdrive reaction plate from the input clutch retainer (Fig. 68). NOTE: The overdrive friction discs and steel discs are thicker than the matching components in the underdrive and reverse clutches. 9. Remove the number 2 bearing from the input clutch hub. 10. Remove the overdrive clutch wave snap-ring from the input clutch retainer. 11. Remove the UD/OD reaction plate tapered snap-ring from the input clutch retainer. 12. Remove the UD/OD reaction plate from the input clutch retainer. 13. Remove the UD/OD reaction plate flat snap-ring from the input clutch retainer (Fig. 68). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Input Clutch > Page 3515 14. Remove the underdrive clutch pack from the input clutch retainer (Fig. 70). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Input Clutch > Page 3516 15. Using Spring Compressor 8251, compress the UD/01) balance piston and remove the snap-ring from the input clutch hub (Fig. 69). 16. Remove the UD/01) balance piston and piston return spring from the input clutch retainer (Fig. 70). 17. Remove the underdrive piston from the input clutch retainer (Fig. 70). NOTE: Both the UD/OD balance piston and the underdrive piston have seals molded onto them. If the seal is damaged, do not attempt to install a new seal onto the piston. The piston/seal must be replaced as an assembly. 18. Remove the input clutch retainer tapered snap-ring. 19. Separate input clutch retainer from input clutch hub. 20. Separate OD/reverse piston from input clutch hub retainer (Fig. 70). 21. Remove all seals and O-rings from the input shaft and input hub. The O-rings on the input hub are color coded. Be sure to make note of which O-ring belongs in which location. ASSEMBLY 1. Install all new seals and O-rings onto the input shaft and input hub. The O-rings on the input hub are color coded. Be sure to install the correct O-ring in the correct location. 2. Check the transmission lubrication check valve located in the input shaft using shop air. The valve should only allow air flow in one direction. If the valve allows no air flow, or air flow in both directions, the valve will need to be replaced. 3. Lubricate all seals with Mopar(R) ATF +4, type 9602, prior to installation. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Input Clutch > Page 3517 4. Assemble the OD/reverse piston onto the input clutch hub (Fig. 71). 5. Assemble the input clutch retainer onto the input clutch hub. 6. Install the input clutch retainer tapered snap-ring with tapered side up onto the input clutch hub. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Input Clutch > Page 3518 7. Install Piston Guides 8504 into the input clutch retainer (Fig. 72) and onto the input clutch hub to guide the inner and outer underdrive piston seals into position. 8. Install the underdrive piston into the input clutch retainer and over the input clutch hub (Fig. 71). 9. Install the UD/OD balance piston return spring pack into the input clutch retainer. 10. Install Piston Guide 8252 into the input clutch retainer (Fig. 73) to guide the UD/OD balance piston seal into position inside the underdrive piston. 11. Install the UD/OD balance piston into the input clutch retainer and the underdrive piston. 12. Using Spring Compressor 8251, compress the UD/OD return spring pack and secure the piston in place with the snap-ring (Fig. 74). 13. Install the underdrive clutch pack into the input clutch retainer (Fig. 71). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Input Clutch > Page 3519 14. Install the MOD reaction plate lower flat snap-ring (Fig. 75). The correct snap-ring can be identified by the two tabbed ears. 15. Install the MOD reaction plate into the input clutch retainer. The reaction plate is to be installed with the big step down. 16. Install the MOD reaction plate upper tapered snap-ring with tapered side up. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Input Clutch > Page 3520 17. Install the input clutch assembly into Input Clutch Pressure Fixture 8260 (Fig. 76). Mount a dial indicator to the assembly, push down on the clutch discs and zero the indicator against the underdrive clutch discs (Fig. 77). Apply 20 psi of air pressure to the underdrive clutch and record the dial indicator reading. Measure and record LTD clutch pack measurement in four (4) places, 90° apart. Take average of four measurements and compare with UD clutch pack clearance specification. The correct clutch clearance is 0.76 - 1.16 mm (0.030 - 0.063 inch). The reaction plate is not selective. If the clutch clearance is not within specification, replace the reaction plate along with all the friction and steel discs. 18. Install the overdrive clutch pack into the input clutch retainer (Fig. 75). The overdrive steel separator plates can be identified by the lack of the half-moon cuts in the locating tabs. 19. Install the overdrive clutch wavy snap-ring with the two tabbed ears into the input clutch retainer. 20. Install the OD/reverse reaction plate into the input clutch retainer. The reaction plate is non-directional (Fig. 75). 21. Install the OD/reverse reaction plate flat snap-ring into the input clutch retainer. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Input Clutch > Page 3521 22. Mount a dial indicator to the assembly and zero the indicator against the OD/reverse reaction plate (Fig. 78). Apply 20 psi of air pressure to the overdrive clutch and record the dial indicator reading. Measure and record OD clutch pack measurement in four (4) places, 90° apart. Take average of four measurements and compare with OD clutch pack clearance specification. Verify that the clutch clearance is 1.016 - 1.65 mm (0.040 0.065 inch). The reaction plate is not selective. If the clutch clearance is not within specification, replace the reaction plate along with all the friction and steel discs. 23. Install the reverse clutch pack into the input clutch retainer (Fig. 75). 24. Install the reverse reaction plate into the input clutch retainer. 25. Install the reverse reaction plate selective snap-ring into the input clutch retainer. 26. Mount a dial indicator to the assembly, push down on the clutch discs, pull up on the reaction plate to ensure the plate is properly seated and zero the indicator against the reverse clutch discs (Fig. 79). Apply 20 psi of air pressure to the reverse clutch and record the dial indicator reading. Measure and record Reverse clutch pack measurement in four 4 places, 90° apart. Take average of four measurements and compare with Reverse clutch pack clearance specification. The correct clutch clearance is 0.81 - 1.24 mm (0.032 - 0.049 inch). Adjust as necessary. Install the chosen snap-ring and re-measure to verify selection. 27. Remove the reverse clutch pack from the input clutch retainer. 28. Install the number 2 bearing onto the underdrive hub with flat side up/forward with petroleum jelly. 29. Install the underdrive hub into the input clutch retainer. 30. Install the number 3 bearing into the overdrive hub with the flat side up/forward with petroleum jelly. 31. Install the overdrive hub into the input clutch retainer. 32. Install the number 4 bearing into the reverse hub with flat side up/forward with petroleum jelly. 33. Install the reverse hub into the input clutch retainer. 34. Install the complete reverse clutch pack. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Input Clutch > Page 3522 35. Install the reverse reaction plate and snap-ring. 36. Push up on reaction plate to allow reverse clutch to move freely. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Input Clutch > Page 3523 Clutch: Service and Repair Low / Reverse Clutch Disassembly DISASSEMBLY 1. Remove the inner overrunning clutch snap-ring from the low/reverse clutch retainer (Fig. 82). 2. Remove the outer low/reverse reaction plate flat snap-ring (Fig. 82). 3. Remove the low/reverse clutch and the overrunning clutch from the low/reverse clutch retainer as an assembly (Fig. 82). 4. Separate the low/reverse clutch from the overrunning clutch. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Input Clutch > Page 3524 5. Remove the overrunning clutch snap-ring (Fig. 83). 6. Remove the spacer from the overrunning clutch (Fig. 83). 7. Separate the inner and outer races of the over- running clutch (Fig. 83). 8. Remove the overrunning clutch lower snap-ring (Fig. 83). 9. Using Spring Compressor 8285 and a suitable shop press (Fig. 84), compress the low/reverse piston Belleville spring and remove the split retaining ring 10. Remove the low/reverse clutch Belleville spring and piston from the low/reverse clutch retainer. Use 20 psi of air pressure to remove the piston if necessary. Cleaning and Inspection CLEANING Clean the overrunning clutch assembly, clutch cam, and low-reverse clutch retainer. Dry them with compressed air after cleaning. INSPECTION Inspect condition of each clutch part after cleaning. Replace the overrunning clutch roller and spring assembly if any rollers or springs are worn or damaged, or if the roller cage is distorted, or damaged. Replace the cam if worn, cracked or damaged. Replace the low-reverse clutch retainer if the clutch race, roller surface or inside diameter is scored, worn or damaged. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Input Clutch > Page 3525 Assembly ASSEMBLY 1. Check the bleed orifice to ensure that it is not plugged or restricted. 2. Install a new seal on the low/reverse piston. Lubricate the seal with Mopar(R) ATF +4, type 9602, prior to installation. 3. Install the low/reverse piston into the low/reverse clutch retainer. 4. Position the low/reverse piston Belleville spring on the low/reverse piston. 5. Using Spring Compressor 8285 and a suitable shop press (Fig. 84), compress the low/reverse piston Belleville spring and install the split retaining ring to hold the Belleville spring into the low/reverse clutch retainer. 6. Install the lower overrunning clutch snap-ring (Fig. 83). 7. Assemble the inner and outer races of the overrunning clutch (Fig. 83). 8. Position the overrunning clutch spacer on the overrunning clutch. 9. Install the upper overrunning clutch snap-ring (Fig. 83). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Input Clutch > Page 3526 10. Assemble and install the low/reverse clutch pack into the low/reverse clutch retainer (Fig. 82). 11. Install the low/reverse reaction plate into the low/reverse clutch retainer (Fig. 82). The reaction plate is directional and must be installed with the flat side down. 12. Install the low/reverse clutch pack snap-ring (Fig. 82). The snap-ring is selectable and should be chosen to give the correct clutch pack clearance. 13. Measure the low/reverse clutch pack clearance and adjust as necessary. The correct clutch clearance is 1.14 - 1.91 mm (0.045 - 0.075 inch). 14. Install the overrunning clutch into the low/reverse clutch retainer making sure that the index splines are aligned with the retainer. 15. Install the overrunning clutch inner snap-ring. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > Customer Interest for Transmission Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts Transmission Control Module: Customer Interest A/T - 45RFE/545RFE Harsh Upshifts/Downshifts NUMBER: 18-025-01 GROUP: Vehicle Performance DATE: October 15, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-09-00, DATED SEPTEMBER 15, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. **ASTERISKS** HAVE BEEN USED TO HIGHLIGHT CHANGES. THIS BULLETIN ADDS A MODEL YEAR AND REQUIRES A REPROGRAMMING OF THE 1999 AND 2000 GRAND CHEROKEE POWERTRAIN CONTROL MODULE (PCM). SUBJECT: 45RFE **and 545RFE Shift** Quality Enhancements for the** 2-3, 4-5, and 5-4** Shifts OVERVIEW: This bulletin involves selectively erasing and reprogramming the **Transmission Control Module (TCM) with new software: '99-'01 WJ (PN 05019701AC Ver 9.3), '00 AN/DN (PN 05018454AB Ver 9.1), or '01 AN/DN (PN 56028285A1 Ver 8.4), and requires reprogramming of the Powertrain Control Module (PCM) for the 1999 and 2000 Grand Cherokees only (with calibration 99Cal20 (1999) or 00Cal17 (2000).** NOTE: THE 2001 GRAND CHEROKEE DOES NOT REQUIRE REPROGRAMMING OF THE PCM AS IT IS ALREADY AT THE CORRECT CALIBRATION LEVEL. NOTE: WHENEVER A PCM OR TCM IS REPLACED OR REPROGRAMMED, THE SOFTWARE OF THE PCM MUST BE VERIFIED AS HAVING THE LATEST REVISION LEVEL. MODELS: 2000 (AN) Dakota **2001** 2000 (DN) Durango **2001** 1999 (WJ) Grand Cherokee **2001 ** NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 4.7L ENGINE AND A 45RFE **OR 545RFE** TRANSMISSION. SYMPTOM/CONDITION: Some vehicles **may exhibit one or more of the following performance conditions **: 1. A harsh 2-3 upshift causing a powertrain clunk or shudder when accelerating. 2. **A harsh 4-5 upshift ('01 Grand Cherokee only).** 3. **A harsh 5-4 downshift ('01 Grand Cherokee only).** NOTE: THIS REVISION TO THE TCM SOFTWARE ADDRESSES THE ABOVE SHIFT QUALITY CONDITIONS FOR ALL VEHICLES AND, ADDS A FINAL GEAR RATIO TO THE **1999 AND 2000 MY** GRAND CHEROKEE TRANSMISSION ONLY. (2001 MY GRAND CHEROKEE ALREADY HAS THIS UPGRADE.) NOTE: TO MAINTAIN EMISSIONS COMPLIANCE, GRAND CHEROKEE VEHICLES THAT ARE EQUIPPED WITH A FEDERAL EMISSION SYSTEM (SALES CODE NAA) MUST HAVE THEIR PCM REPROGRAMMED. IF THE SOFTWARE LEVEL IS AT OR HIGHER THAN THOSE IN THE OVERVIEW ABOVE, OR IF THE GRAND CHEROKEE HAS A CALIFORNIA EMISSIONS SYSTEM (SALES CODE NAE), REPROGRAMMING IS NOT NECESSARY. DIAGNOSIS PROCEDURES: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRBIII(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 performing this repair. If no DTC's are present, and the above symptom has been experienced, perform the Repair Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > Customer Interest for Transmission Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts > Page 3535 Procedure. NOTE: **IF OTHER PERFORMANCE ISSUES REMAIN AFTER THE REPAIR PROCEDURE HAS BEEN PERFORMED THEY DO NOT RELATE TO THIS BULLETIN. REFER TO THE PROPER SERVICE OR DIAGNOSTIC PROCEDURES MANUAL(S) FOR FURTHER ASSISTANCE.** PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD **2093 OR HIGHER AND DRB III(R) VERSION 52.3 WILL BE IN THE DEALERSHIPS ON OCTOBER 15, 2001.)** REPAIR PROCEDURE: 1. Log onto the MDS2 (Mopar Diagnostic System). 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III(R), MDS2, AND VEHICLE ESTABLISH COMMUNICATION. 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. 3. Push the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) 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. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. 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, 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 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > Customer Interest for Transmission Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts > Page 3536 7. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 8. 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts Transmission Control Module: All Technical Service Bulletins A/T - 45RFE/545RFE Harsh Upshifts/Downshifts NUMBER: 18-025-01 GROUP: Vehicle Performance DATE: October 15, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-09-00, DATED SEPTEMBER 15, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. **ASTERISKS** HAVE BEEN USED TO HIGHLIGHT CHANGES. THIS BULLETIN ADDS A MODEL YEAR AND REQUIRES A REPROGRAMMING OF THE 1999 AND 2000 GRAND CHEROKEE POWERTRAIN CONTROL MODULE (PCM). SUBJECT: 45RFE **and 545RFE Shift** Quality Enhancements for the** 2-3, 4-5, and 5-4** Shifts OVERVIEW: This bulletin involves selectively erasing and reprogramming the **Transmission Control Module (TCM) with new software: '99-'01 WJ (PN 05019701AC Ver 9.3), '00 AN/DN (PN 05018454AB Ver 9.1), or '01 AN/DN (PN 56028285A1 Ver 8.4), and requires reprogramming of the Powertrain Control Module (PCM) for the 1999 and 2000 Grand Cherokees only (with calibration 99Cal20 (1999) or 00Cal17 (2000).** NOTE: THE 2001 GRAND CHEROKEE DOES NOT REQUIRE REPROGRAMMING OF THE PCM AS IT IS ALREADY AT THE CORRECT CALIBRATION LEVEL. NOTE: WHENEVER A PCM OR TCM IS REPLACED OR REPROGRAMMED, THE SOFTWARE OF THE PCM MUST BE VERIFIED AS HAVING THE LATEST REVISION LEVEL. MODELS: 2000 (AN) Dakota **2001** 2000 (DN) Durango **2001** 1999 (WJ) Grand Cherokee **2001 ** NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 4.7L ENGINE AND A 45RFE **OR 545RFE** TRANSMISSION. SYMPTOM/CONDITION: Some vehicles **may exhibit one or more of the following performance conditions **: 1. A harsh 2-3 upshift causing a powertrain clunk or shudder when accelerating. 2. **A harsh 4-5 upshift ('01 Grand Cherokee only).** 3. **A harsh 5-4 downshift ('01 Grand Cherokee only).** NOTE: THIS REVISION TO THE TCM SOFTWARE ADDRESSES THE ABOVE SHIFT QUALITY CONDITIONS FOR ALL VEHICLES AND, ADDS A FINAL GEAR RATIO TO THE **1999 AND 2000 MY** GRAND CHEROKEE TRANSMISSION ONLY. (2001 MY GRAND CHEROKEE ALREADY HAS THIS UPGRADE.) NOTE: TO MAINTAIN EMISSIONS COMPLIANCE, GRAND CHEROKEE VEHICLES THAT ARE EQUIPPED WITH A FEDERAL EMISSION SYSTEM (SALES CODE NAA) MUST HAVE THEIR PCM REPROGRAMMED. IF THE SOFTWARE LEVEL IS AT OR HIGHER THAN THOSE IN THE OVERVIEW ABOVE, OR IF THE GRAND CHEROKEE HAS A CALIFORNIA EMISSIONS SYSTEM (SALES CODE NAE), REPROGRAMMING IS NOT NECESSARY. DIAGNOSIS PROCEDURES: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRBIII(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 performing this repair. If no DTC's are present, and the above symptom has been experienced, perform the Repair Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts > Page 3542 Procedure. NOTE: **IF OTHER PERFORMANCE ISSUES REMAIN AFTER THE REPAIR PROCEDURE HAS BEEN PERFORMED THEY DO NOT RELATE TO THIS BULLETIN. REFER TO THE PROPER SERVICE OR DIAGNOSTIC PROCEDURES MANUAL(S) FOR FURTHER ASSISTANCE.** PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD **2093 OR HIGHER AND DRB III(R) VERSION 52.3 WILL BE IN THE DEALERSHIPS ON OCTOBER 15, 2001.)** REPAIR PROCEDURE: 1. Log onto the MDS2 (Mopar Diagnostic System). 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III(R), MDS2, AND VEHICLE ESTABLISH COMMUNICATION. 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. 3. Push the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) 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. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. 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, 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 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts > Page 3543 7. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 8. 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > Page 3544 Transmission Control Module: Locations Fig. 13 Transmission Control Module Location The Transmission Control Module (TCM) is located in the engine compartment on the right (passenger) side and is mounted to the radiator core support. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions Transmission Control Module: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3547 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3548 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3549 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3550 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3551 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3552 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3553 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3554 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3555 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3556 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3557 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3558 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3559 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3560 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3561 Transmission Control Module: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3562 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3563 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3564 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3565 Transmission Control Module: Connector Views Transmission Control Module Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3566 Transmission Control Module Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3567 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 3568 Transmission Control Module: Description and Operation Fig. 13 Transmission Control Module Location The Transmission Control Module (TCM) is located in the engine compartment on the right (passenger) side and is mounted to the radiator core support (Fig. 13). The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hardwired to, and used specifically by the TCM. Indirect inputs originate from other components/modules, and are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - DRB Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 3569 - Transmission Temperature (to PCM) - PRNDL Position (to BCM) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with DRB scan tool) NOTE: If the TCM has been replaced, the "Quick Learn Procedure" must be performed. (Refer to ELECTRONIC CONTROL MODULES/ TRANSMISSION CONTROL MODULE - STANDARD PROCEDURE) Battery Feed A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain adaptive learn values in the TCM's RAM (Random Access Memory). When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. Clutch Volume Indexes (CVI) An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. Fig. 14 Example Of CVI Calculation By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur (Fig. 14). Gear ratios can be determined by using the DRB Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 3570 The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Clutch Volumes Certain mechanical problems within the input clutch assembly (broken return springs, out of position snap rings, excessive clutch pack clearance, improper assembly, etc.) can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following chart identifies the appropriate clutch volumes and when they are monitored/updated: Shift Schedules As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 3571 Driving Conditions As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 3572 Transmission Control Module: Service and Repair STANDARD PROCEDURES The quick learn procedure requires the use of the DRB scan tool. This program allows the electronic transmission system to recalibrate itself. This will provide the proper transmission operation. The quick learn procedure should be performed if any of the following procedures are performed: Transmission Assembly Replacement - Transmission Control Module Replacement - Solenoid Pack Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees. - The shift lever position must stay in PARK until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the DRB III indicates the procedure is complete - The calculated oil temperature must be above 60 ° and below 200 ° Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications Extension Housing: Specifications Bolt, extension housing 40 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3580 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3581 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3582 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3583 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3584 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid Capacity Model 42RE, 44RE, 46RE ................................................................................................................... ............................................ 9.1-9.5Liters (19-20 Pt) Model 45RFE ....................................................................................................................................... ................................................. 13.33Liters (28.0 Pt) Capacities may vary. Check fluid level on dipstick according to applicable procedures. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 3587 Fluid - A/T: Fluid Type Specifications A/T Fluid Type Model 42RE, 46RE, 45RFE ...................................................................................................................................................... Mopar ATF + 4, Type 9602 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 3588 Fluid - A/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Effects of Incorrect Fluid Level Fluid - A/T: Testing and Inspection Effects of Incorrect Fluid Level EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be low and develop slower than normal. If the transmission is overfilled, the gears chum the fluid into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid overheating, oxidation and varnish buildup which interferes with valve and clutch operation. Foaming also causes fluid expansion which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Effects of Incorrect Fluid Level > Page 3591 Fluid - A/T: Testing and Inspection Causes of Burnt Fluid CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has three primary causes. 1. Internal clutch slippage, usually caused by low line pressure, inadequate clutch apply pressure, or clutch seal failure. 2. A result of restricted fluid flow through the main and/or auxiliary cooler. This condition is usually the result of a faulty or improperly installed drainback valve, a damaged main cooler, or severe restrictions in the coolers and lines caused by debris or kinked lines. 3. Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to handle heavy loads. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Effects of Incorrect Fluid Level > Page 3592 Fluid - A/T: Testing and Inspection Fluid Contamination FLUID CONTAMINATION Transmission fluid contamination is generally a result of: - adding incorrect fluid - failure to clean dipstick and fill tube when checking level - engine coolant entering the fluid - internal failure that generates debris - overheat that generates sludge (fluid breakdown) - failure to reverse flush cooler and lines after repair - failure to replace contaminated converter after repair The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary. The transmission cooler and lines should be reverse flushed whenever a malfunction generates sludge and/or debris. The torque converter should also be replaced at the same time. Failure to flush the cooler and lines will result in recontamination. Flushing applies to auxiliary coolers as well. The torque converter should also be replaced whenever a failure generates sludge and debris. This is necessary because normal converter flushing procedures will not remove all contaminants. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check Fluid - A/T: Service and Repair Fluid Level Check FLUID LEVEL CHECK Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmission has too much fluid, the geartrain churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. Along with fluid level, it is important to check the condition of the fluid. When the fluid smells burned, and is contaminated with metal or friction material particles, a complete transmission recondition is needed. Be sure to examine the fluid on the dipstick closely. If there is any doubt about its condition, drain out a sample for a double check. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. The transmission has a dipstick to check oil level. It is located on the right side of the engine. Be sure to wipe all dirt from dipstick handle before removing. The torque converter fills in both the P (PARK) and N (NEUTRAL) positions. Place the selector lever in P (PARK) to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature (approximately 82°C. or 180°F.), the fluid level is correct if it is in the HOT region (cross-hatched area) on the oil level indicator. The fluid level will be approximately at the upper COLD hole of the dipstick at 70°F fluid temperature. NOTE: Engine and Transmission should be at normal operating temperature before performing this procedure. 1. Start engine and apply parking brake. 2. Shift the transmission into DRIVE for approximately 2 seconds. 3. Shift the transmission into REVERSE for approximately 2 seconds. 4. Shift the transmission into PARK. 5. Hook up DRB@ scan tool and select transmission. 6. Select sensors. 7. Read the transmission temperature value. 8. Compare the fluid temperature value with the chart. 9. Adjust transmission fluid level shown on the dipstick according to the chart. NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the transmission before rechecking the fluid level. 10. Check transmission for leaks. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check > Page 3595 Fluid - A/T: Service and Repair Fluid and Filter Service STANDARD PROCEDURE - FLUID AND FILTER REPLACEMENT REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission. 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolts holding pan to transmission. 7. While holding pan level, lower pan away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove screw holding filter to valve body (Fig. 54). 10. Separate filter from valve body and oil pump and pour fluid in filter into drain pan. 11. Remove and discard the oil filter seal from the bottom of the oil pump. 12. If replacing the cooler return filter, use Oil Filter Wrench 8321 to remove the filter from the transmission. 13. Dispose of used trans fluid and filter(s) properly. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check > Page 3596 Transmission Fluid Temperature Chart INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION 1. Install a new oil filter seal into the bottom of the oil pump. NOTE: Do not attempt to install the seal onto the oil filter first and then into the oil pump. An unsatisfactory seal between the oil pump and filter will result, allowing air to be drawn into the pump. 2. Place replacement filter in position on valve body and into the oil pump. 3. Install screw to hold filter to valve body (Fig. 54). Tighten screw to 4.5 Nm (40 inch lbs.) torque. 4. Install new cooler return filter onto the transmission, if necessary. Torque the filter to 14.12 Nm (125 inch lbs.). 5. Place bead of Mopar(R) RTV sealant onto the transmission case sealing surface. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 11.8 Nm (105 inch lbs.) torque. 8. Lower vehicle and fill transmission with Mopar(R) ATF +4, type 9602 fluid. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check > Page 3597 Fluid - A/T: Service and Repair Transmission Fill TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar(R) ATF +4 to transmission: a. If only fluid and filter were changed, add 10 pints (5 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled, torque converter was replaced or drained, and cooler was flushed, add 24 pints (12 quarts) of ATF +4 to transmission. 3. Check the transmission fluid and adjust as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; Fluid Filter - A/T: Customer Interest A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; NUMBER: 21-015-05 GROUP: Transmission DATE: September 01, 2005 SUBJECT: 45RFE / 545RFE Trans - Delayed Engagement Due To Cooler Return Filter Replacement OVERVIEW: This bulletin involves a transmission delayed shift condition that may occur following the replacement of the internal cooler return filter. MODELS: 2000 - 2004 (AN) Dakota 2000 - 2003 (DN) Durango 2003 - 2006 (DR) Ram Truck 2004 - 2006 (HB) Durango 2002 - 2006 (KJ) Liberty 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - 2006 (WK/WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with a 45RFE or a 545RFE automatic transmission (sales code DG4 or DGQ respectively). DISCUSSION: The customer may experience an initial delayed shift engagement following an extended off (not running) period of time, generally after being parked overnight. The initial shift engagement may feel like a delay or slip when a transmission gear (reverse or drive) is first selected after engine start. The customer may not have experienced the delayed shift engagement until after the transmission has been serviced, where the cooler return filter was replaced during the service and/or repair. The condition is not detrimental to the transmission but may cause concern with the customer. The above condition may be caused by a suspect cooler return filter a part number of 04799662AB. This "AB" suffix / level filter may allow transmission fluid to drain back out of the torque converter. The drain back condition may occur over a period time when the engine (and transmission) are not running. With less fluid in the torque converter a delay in gear engagement may occur at engine start up while the torque converter fills to its proper fluid level. All 04799662AB cooler return filters with the "AB" suffix are suspect. The above condition may be corrected by replacing a suspect "AB" filter with a new cooler return filter whose part number is 04799662 (with no suffix or with a suffix that is other than the "AB" level). NOTE: The cooler return filter, p/n 04799662, will not be available until September 09, 2005. The filter part number is stenciled on the side of the filter case. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; > Page 3606 NOTE: A replacement 04799662 cooler return filter may come packaged with a separate threaded adapter stud. The threaded adapter stud is used to attach the cooler return filter to the transmission. Inspect the stud and note end without threads. Install the stud end without the threads into the cooler return filter and tighten the stud-to-filter connection to 18.6 Nm (165 in. lbs.). Once the threaded adapter stud has been installed to the cooler return filter, install the assembled cooler return filter to the transmission and tighten the filter to 14.1 Nm (125 in. lbs.) POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; Fluid Filter - A/T: All Technical Service Bulletins A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; NUMBER: 21-015-05 GROUP: Transmission DATE: September 01, 2005 SUBJECT: 45RFE / 545RFE Trans - Delayed Engagement Due To Cooler Return Filter Replacement OVERVIEW: This bulletin involves a transmission delayed shift condition that may occur following the replacement of the internal cooler return filter. MODELS: 2000 - 2004 (AN) Dakota 2000 - 2003 (DN) Durango 2003 - 2006 (DR) Ram Truck 2004 - 2006 (HB) Durango 2002 - 2006 (KJ) Liberty 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - 2006 (WK/WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with a 45RFE or a 545RFE automatic transmission (sales code DG4 or DGQ respectively). DISCUSSION: The customer may experience an initial delayed shift engagement following an extended off (not running) period of time, generally after being parked overnight. The initial shift engagement may feel like a delay or slip when a transmission gear (reverse or drive) is first selected after engine start. The customer may not have experienced the delayed shift engagement until after the transmission has been serviced, where the cooler return filter was replaced during the service and/or repair. The condition is not detrimental to the transmission but may cause concern with the customer. The above condition may be caused by a suspect cooler return filter a part number of 04799662AB. This "AB" suffix / level filter may allow transmission fluid to drain back out of the torque converter. The drain back condition may occur over a period time when the engine (and transmission) are not running. With less fluid in the torque converter a delay in gear engagement may occur at engine start up while the torque converter fills to its proper fluid level. All 04799662AB cooler return filters with the "AB" suffix are suspect. The above condition may be corrected by replacing a suspect "AB" filter with a new cooler return filter whose part number is 04799662 (with no suffix or with a suffix that is other than the "AB" level). NOTE: The cooler return filter, p/n 04799662, will not be available until September 09, 2005. The filter part number is stenciled on the side of the filter case. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; > Page 3612 NOTE: A replacement 04799662 cooler return filter may come packaged with a separate threaded adapter stud. The threaded adapter stud is used to attach the cooler return filter to the transmission. Inspect the stud and note end without threads. Install the stud end without the threads into the cooler return filter and tighten the stud-to-filter connection to 18.6 Nm (165 in. lbs.). Once the threaded adapter stud has been installed to the cooler return filter, install the assembled cooler return filter to the transmission and tighten the filter to 14.1 Nm (125 in. lbs.) POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Page 3613 Fluid Filter - A/T: Specifications Screws, fluid filter 35 in.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Level Check Fluid Filter - A/T: Service and Repair Fluid Level Check FLUID LEVEL CHECK Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmission has too much fluid, the geartrain churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. Along with fluid level, it is important to check the condition of the fluid. When the fluid smells burned, and is contaminated with metal or friction material particles, a complete transmission recondition is needed. Be sure to examine the fluid on the dipstick closely. If there is any doubt about its condition, drain out a sample for a double check. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. The transmission has a dipstick to check oil level. It is located on the right side of the engine. Be sure to wipe all dirt from dipstick handle before removing. The torque converter fills in both the P (PARK) and N (NEUTRAL) positions. Place the selector lever in P (PARK) to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature (approximately 82°C. or 180°F.), the fluid level is correct if it is in the HOT region (cross-hatched area) on the oil level indicator. The fluid level will be approximately at the upper COLD hole of the dipstick at 70°F fluid temperature. NOTE: Engine and Transmission should be at normal operating temperature before performing this procedure. 1. Start engine and apply parking brake. 2. Shift the transmission into DRIVE for approximately 2 seconds. 3. Shift the transmission into REVERSE for approximately 2 seconds. 4. Shift the transmission into PARK. 5. Hook up DRB@ scan tool and select transmission. 6. Select sensors. 7. Read the transmission temperature value. 8. Compare the fluid temperature value with the chart. 9. Adjust transmission fluid level shown on the dipstick according to the chart. NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the transmission before rechecking the fluid level. 10. Check transmission for leaks. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Level Check > Page 3616 Fluid Filter - A/T: Service and Repair Fluid and Filter Service STANDARD PROCEDURE - FLUID AND FILTER REPLACEMENT REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission. 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolts holding pan to transmission. 7. While holding pan level, lower pan away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove screw holding filter to valve body (Fig. 54). 10. Separate filter from valve body and oil pump and pour fluid in filter into drain pan. 11. Remove and discard the oil filter seal from the bottom of the oil pump. 12. If replacing the cooler return filter, use Oil Filter Wrench 8321 to remove the filter from the transmission. 13. Dispose of used trans fluid and filter(s) properly. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Level Check > Page 3617 Transmission Fluid Temperature Chart INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION 1. Install a new oil filter seal into the bottom of the oil pump. NOTE: Do not attempt to install the seal onto the oil filter first and then into the oil pump. An unsatisfactory seal between the oil pump and filter will result, allowing air to be drawn into the pump. 2. Place replacement filter in position on valve body and into the oil pump. 3. Install screw to hold filter to valve body (Fig. 54). Tighten screw to 4.5 Nm (40 inch lbs.) torque. 4. Install new cooler return filter onto the transmission, if necessary. Torque the filter to 14.12 Nm (125 inch lbs.). 5. Place bead of Mopar(R) RTV sealant onto the transmission case sealing surface. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 11.8 Nm (105 inch lbs.) torque. 8. Lower vehicle and fill transmission with Mopar(R) ATF +4, type 9602 fluid. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Level Check > Page 3618 Fluid Filter - A/T: Service and Repair Transmission Fill TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar(R) ATF +4 to transmission: a. If only fluid and filter were changed, add 10 pints (5 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled, torque converter was replaced or drained, and cooler was flushed, add 24 pints (12 quarts) of ATF +4 to transmission. 3. Check the transmission fluid and adjust as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications Fluid Line/Hose: Specifications Fitting, cooler lines at transmission 13 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications > Page 3622 Fluid Line/Hose: Service and Repair FLUSHING COOLERS AND TUBES When a transmission failure has contaminated the fluid, the oil cooler(s) must be flushed. The torque converter must also be replaced. This will insure that metal particles or sludged oil are not later transferred back into the reconditioned (or replaced) transmission. The only recommended procedure for flushing coolers and lines is to use Tool 6906-B Cooler Flusher. WARNING: WEAR PROTECTIVE EYE WEAR THAT MEETS THE REQUIREMENTS OF OSHA AND ANSI Z87.1-1968. WEAR STANDARD INDUSTRIAL RUBBER GLOVES. KEEP LIGHTED CIGARETTES, SPARKS, FLAMES, AND OTHER IGNITION SOURCES AWAY FROM THE AREA TO PREVENT THE IGNITION OF COMBUSTIBLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE EXTINGUISHER IN THE AREA WHERE THE FLUSHER WILL BE USED. KEEP THE AREA WELL VENTILATED. DO NOT LET FLUSHING SOLVENT COME IN CONTACT WITH YOUR EYES OR SKIN: IF EYE CONTAMINATION OCCURS, FLUSH EYES WITH WATER FOR 15 TO 20 SECONDS. REMOVE CONTAMINATED CLOTHING AND WASH AFFECTED SKIN WITH SOAP AND WATER. SEEK MEDICAL ATTENTION. 1. Remove cover plate filler plug on Tool 6906-B. Fill reservoir 1/2 to 3/4 full of fresh flushing solution. Flushing solvents are petroleum based solutions generally used to clean automatic transmission components. DO NOT use solvents containing acids, water, gasoline, or any other corrosive liquids. 2. Reinstall filler plug on Tool 6906-B. 3. Verify pump power switch is turned OFF. Connect red alligator clip to positive (+) battery post. Connect black W alligator clip to a good ground. 4. Disconnect the cooler lines at the transmission. NOTE: When flushing transmission cooler and lines, ALWAYS reverse flush. NOTE: The converter drainback valve must be removed and an appropriate replacement hose installed to bridge the space between the transmission cooler line and the cooler fitting. Failure to remove the drainback valve will prevent reverse flushing the system. A suitable replacement hose can be found in the adapter kit supplied with the flushing tool. 5. Connect the BLUE pressure line to the OUTLET (From) cooler line. 6. Connect the CLEAR return line to the INLET (To) cooler line 7. Turn pump ON for two to three minutes to flush cooler(s) and lines. 8. Turn pump OFF. 9. Disconnect CLEAR suction line from reservoir at cover plate. Disconnect CLEAR return line at cover plate, and place it in a drain pan. 10. Turn pump ON for 30 seconds to purge flushing solution from cooler and lines. Turn pump OFF. 11. Place CLEAR suction line into a one quart container of Mopar ATF +4, type 9602, Automatic Transmission Fluid. 12. Turn pump ON until all transmission fluid is removed from the one quart container and lines. This purges any residual cleaning solvent from the transmission cooler and lines. Turn pump OFF. 13. Disconnect alligator clips from battery. Reconnect flusher lines to cover plate, and remove flushing adapters from cooler lines. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications Torque Specifications Torque Specifications Transmission Component Torque 42RE, 44RE Bolt, Fluid Pan 17 Nm (13 ft. lbs.) 46RE " 17 Nm (13 ft. lbs.) 45RFE " 11.8 Nm (105 in. lbs.) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Service and Repair > Fluid Level Check Fluid Pan: Service and Repair Fluid Level Check FLUID LEVEL CHECK Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmission has too much fluid, the geartrain churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. Along with fluid level, it is important to check the condition of the fluid. When the fluid smells burned, and is contaminated with metal or friction material particles, a complete transmission recondition is needed. Be sure to examine the fluid on the dipstick closely. If there is any doubt about its condition, drain out a sample for a double check. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. The transmission has a dipstick to check oil level. It is located on the right side of the engine. Be sure to wipe all dirt from dipstick handle before removing. The torque converter fills in both the P (PARK) and N (NEUTRAL) positions. Place the selector lever in P (PARK) to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature (approximately 82°C. or 180°F.), the fluid level is correct if it is in the HOT region (cross-hatched area) on the oil level indicator. The fluid level will be approximately at the upper COLD hole of the dipstick at 70°F fluid temperature. NOTE: Engine and Transmission should be at normal operating temperature before performing this procedure. 1. Start engine and apply parking brake. 2. Shift the transmission into DRIVE for approximately 2 seconds. 3. Shift the transmission into REVERSE for approximately 2 seconds. 4. Shift the transmission into PARK. 5. Hook up DRB@ scan tool and select transmission. 6. Select sensors. 7. Read the transmission temperature value. 8. Compare the fluid temperature value with the chart. 9. Adjust transmission fluid level shown on the dipstick according to the chart. NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the transmission before rechecking the fluid level. 10. Check transmission for leaks. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Service and Repair > Fluid Level Check > Page 3628 Fluid Pan: Service and Repair Fluid and Filter Service STANDARD PROCEDURE - FLUID AND FILTER REPLACEMENT REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission. 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolts holding pan to transmission. 7. While holding pan level, lower pan away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove screw holding filter to valve body (Fig. 54). 10. Separate filter from valve body and oil pump and pour fluid in filter into drain pan. 11. Remove and discard the oil filter seal from the bottom of the oil pump. 12. If replacing the cooler return filter, use Oil Filter Wrench 8321 to remove the filter from the transmission. 13. Dispose of used trans fluid and filter(s) properly. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Service and Repair > Fluid Level Check > Page 3629 Transmission Fluid Temperature Chart INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION 1. Install a new oil filter seal into the bottom of the oil pump. NOTE: Do not attempt to install the seal onto the oil filter first and then into the oil pump. An unsatisfactory seal between the oil pump and filter will result, allowing air to be drawn into the pump. 2. Place replacement filter in position on valve body and into the oil pump. 3. Install screw to hold filter to valve body (Fig. 54). Tighten screw to 4.5 Nm (40 inch lbs.) torque. 4. Install new cooler return filter onto the transmission, if necessary. Torque the filter to 14.12 Nm (125 inch lbs.). 5. Place bead of Mopar(R) RTV sealant onto the transmission case sealing surface. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 11.8 Nm (105 inch lbs.) torque. 8. Lower vehicle and fill transmission with Mopar(R) ATF +4, type 9602 fluid. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Service and Repair > Fluid Level Check > Page 3630 Fluid Pan: Service and Repair Transmission Fill TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar(R) ATF +4 to transmission: a. If only fluid and filter were changed, add 10 pints (5 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled, torque converter was replaced or drained, and cooler was flushed, add 24 pints (12 quarts) of ATF +4 to transmission. 3. Check the transmission fluid and adjust as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair Fluid Pressure Sensor/Switch: Service and Repair LINE PRESSURE (LP) SENSOR REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pressure sensor (Fig. 81). 4. Remove the bolt holding the line pressure sensor to the transmission case. 5. Remove the line pressure sensor from the transmission case. INSTALLATION 1. Install the line pressure sensor into the transmission case. 2. Install the bolt to hold the line pressure sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 in. lbs.). 3. Install the wiring connector onto the line pressure sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications Fluid Pump: Specifications Bolt, oil pump 250 in.lb Bolt, oil pump body to cover 40 in.lb Screw, plate to oil pump body 40 in.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications > Page 3637 Fluid Pump: Description and Operation DESCRIPTION Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications > Page 3638 The oil pump (Fig. 85) is located at the front of the transmission inside the bell housing and behind the transmission front cover. The oil pump consists of two independent pumps (Fig. 86), a number of valves (Fig. 87), a front seal (Fig. 88), and a bolt on reaction shaft. The converter clutch switch and regulator valves, pressure regulator valve, and converter pressure limit valve are all located in the oil pump housing. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications > Page 3639 OPERATION As the torque converter rotates, the converter hub rotates the oil pump drive gear. As the drive gear rotates both driven gears, the clearance between the gear teeth increases in the crescent area, and creates a suction at the inlet side of the pump. This suction draws fluid through the pump inlet from the oil pan. As the clearance between the gear teeth in the crescent area decreases, it forces pressurized fluid into the pump outlet and to the oil pump valves. At low speeds, both pumps supply fluid to the transmission. As the speed of the torque converter increases, the pressure output of both pumps increases until the primary pump pressure reaches the point where it can close off the check valve located between the two pumps. When the check valve is closed, the secondary pump is shut down and the primary pump supplies all the fluid to the transmission. CONVERTER CLUTCH SWITCH VALVE The converter clutch switch valve is used to control the hydraulic pressure supplied to the front (OFF) side of the torque converter clutch. CONVERTER CLUTCH REGULATOR VALVE The converter clutch regulator valve is used to control the hydraulic pressure supplied to the back (ON) side of the torque converter clutch. TORQUE CONVERTER LIMIT VALVE The torque converter limit valve serves to limit the available line pressure to the torque converter clutch to approximately 120 psi. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications > Page 3640 Fluid Pump: Testing and Inspection STANDARD PROCEDURE - OIL PUMP VOLUME CHECK Measuring the oil pump output volume will determine if sufficient oil flow to the transmission oil cooler exists, and whether or not an internal transmission failure is present. Verify that the transmission fluid is at the proper level. Refer to the Fluid Level Check procedure. If necessary, fill the transmission to the proper level with Mopar(R) ATF +4, type 9602, Automatic Transmission Fluid. 1. Disconnect the To cooler line at the cooler inlet and place a collecting container under the disconnected line. CAUTION: With the fluid set at the proper level, fluid collection should not exceed (1) quart or internal damage to the transmission may occur. 2. Run the engine at 1800 rpm, with the shift selector in neutral. Verify that the transmission fluid temperature is below 104.5°C (220°F) for this test. 3. If one quart of transmission fluid is collected in the container in 30 seconds or less, oil pump flow volume is within acceptable limits. If fluid flow is intermittent, or it takes more than 30 seconds to collect one quart of fluid, refer to the Hydraulic Pressure tests for further diagnosis. 4. Re-connect the To cooler line to the transmission cooler inlet. 5. Refill the transmission to proper level. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > Disassembly Fluid Pump: Service and Repair Disassembly DISASSEMBLY 1. Remove the bolts holding the reaction shaft support to the oil pump (Fig. 89). 2. Remove the reaction shaft support from the oil pump (Fig. 89). 3. Remove all bolts holding the oil pump halves together (Fig. 89). 4. Using suitable prying tools, separate the oil pump sections by inserting the tools in the supplied areas and prying the halves apart. NOTE: The oil pump halves are aligned to each other through the use of two dowels. Be sure to pry upward evenly to prevent damage to the oil pump components. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > Disassembly > Page 3643 5. Remove the screws holding the separator plate onto the oil pump body (Fig. 90). 6. Remove the separator plate from the oil pump body (Fig. 90). 7. Mark all gears for location. The gears are select fit and if the oil pump is to be reused, the gears must be returned to their original locations. 8. Remove the oil pump gears from the oil pump case (Fig. 90). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > Disassembly > Page 3644 9. Remove the oil pump valve retainers and associated valve and spring one at a time (Fig. 91) (Fig. 92). Mark the combination of components as a group and tag them as to the location from which they were removed. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > Disassembly > Page 3645 Fluid Pump: Service and Repair Cleaning and Inspection CLEANING Clean pump and support components with solvent and dry them with compressed air. INSPECTION Check condition of the seal rings and thrust washer on the reaction shaft support. The seal rings do not need to be replaced unless cracked, broken, or severely worn. Inspect the pump and support components. Replace the pump or support if the seal ring grooves or machined surfaces are worn, scored, pitted, or damaged. Replace the pump gears if pitted, worn chipped, or damaged. Inspect the pump bushing. Then check the reaction shaft support bushing. Replace either bushing only if heavily worn, scored or damaged. It is not necessary to replace the bushings unless they are actually damaged. 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 oil pump cover. Use a penlight to view the bore interiors. Replace the oil pump if any bores are distorted or scored. Inspect all of the valve springs. The springs must be free of distortion, warpage or broken coils. 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > Disassembly > Page 3646 Fluid Pump: Service and Repair Assembly ASSEMBLY 1. Clean and inspect all components. Make sure that all passages are thoroughly cleaned and are free from dirt or debris. Make sure that all valves move freely in their proper bore. Make sure that A gear pockets and bushings are free from excessive wear and scoring. Replace the oil pump if any excessive wear or scoring is found. 2. Coat the gears with Mopar(R)(R) ATF +4, type 9602, and install into their original locations. 3. Lubricate the oil pump valves with Mopar(R)(R) ATF +4, type 9602, and install the valve, spring and retainer into the appropriate oil pump valve body bore (Fig. 91) (Fig. 92). 4. Place the separator plate onto the oil pump body (Fig. 90). 5. Install the screws to hold the separator plate onto the oil pump body (Fig. 90). Tighten the screws to 4.5 Nm (40 inch lbs.). 6. Position the oil pump cover onto the locating dowels (Fig. 89). 7. Seat the two oil pump halves together and install all bolts finger tight. 8. Torque all bolts down slowly starting in the center and working outward. The correct torque is 4.5 Nm (40 inch lbs.). 9. Verify that the oil pump gears rotate freely and smoothly. 10. Position the reaction shaft support into the oil pump (Fig. 89). 11. Install and torque the bolts to hold the reaction shaft support to the oil pump (Fig. 89). The correct torque is 12 Nm (105 inch lbs.). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Locations Governor: Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Locations > Page 3650 Governor: Description and Operation DESCRIPTION Governor pressure is controlled electronically. Components used for governor pressure control include: Governor body - Valve body transfer plate - Governor pressure solenoid valve - Governor pressure sensor - Fluid temperature thermistor - Throttle position sensor (TPS) - Transmission speed sensor - Powertrain control module (PCM) GOVERNOR PRESSURE SOLENOID VALVE The solenoid valve is a duty-cycle solenoid which regulates the governor pressure needed for upshifts and downshifts. It is an electro-hydraulic device located in the governor body on the valve body transfer plate (Fig. 74). GOVERNOR PRESSURE SENSOR The governor pressure sensor measures output pressure of the governor pressure solenoid valve (Fig. 75). GOVERNOR BODY AND TRANSFER PLATE The transfer plate is designed to supply transmission line pressure to the governor pressure solenoid valve and to return governor pressure. The governor pressure solenoid valve is mounted in the governor body. The body is bolted to the lower side of the transfer plate (Fig. 75). GOVERNOR PRESSURE CURVES There are four governor pressure curves programmed into the transmission control module. The different curves allow the control module to adjust governor pressure for varying conditions. One curve is used for operation when fluid temperature is at, or below, -1°C (30°F). A second curve is used when fluid temperature is at, or above, 10°C (50°F) during normal city or highway driving. A third curve is used during wide-open throttle operation. The fourth curve is used when driving with the transfer case in low range. OPERATION Compensation is required for performance variations of two of the input devices. Though the slope of the transfer functions is tightly controlled, offset Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Locations > Page 3651 may vary due to various environmental factors or manufacturing tolerances. The pressure transducer is affected by barometric pressure as well as temperature. Calibration of the zero pressure offset is required to compensate for shifting output due to these factors. Normal calibration will be performed when sump temperature is above 50 degrees F, or in the absence of sump temperature data, after the first 10 minutes of vehicle operation. Calibration of the pressure transducer offset occurs each time the output shaft speed falls below 200 RPM. Calibration shall be repeated each 3 seconds the output shaft speed is below 200 RPM. A 0.5 second pulse of 95% duty cycle is applied to the governor pressure solenoid valve and the transducer output is read during this pulse. Averaging of the transducer signal is necessary to reject electrical noise. Under cold conditions (below 50 degrees F sump), the governor pressure solenoid valve response may be too slow to guarantee 0 psi during the 0.5 second calibration pulse. Calibration pulses are continued during this period, however the transducer output valves are discarded. Transducer offset must be read at key-on, under conditions which promote a stable reading. This value is retained and becomes the offset during the "cold" period of operation. GOVERNOR PRESSURE SOLENOID VALVE The inlet side of the solenoid valve is exposed to normal transmission line pressure. The outlet side of the valve leads to the valve body governor circuit. The solenoid valve regulates line pressure to produce governor pressure. The average current supplied to the solenoid controls governor pressure. One amp current produces zero kPa/psi governor pressure. Zero amps sets the maximum governor pressure. The powertrain control module (PCM) turns on the trans control relay which supplies electrical power to the solenoid valve. Operating voltage is 12 volts (DC). The PCM controls the ground side of the solenoid using the governor pressure solenoid control circuit. GOVERNOR PRESSURE SENSOR The sensor output signal provides the necessary feedback to the PCM. This feedback is needed to adequately control governor pressure. GOVERNOR BODY AND TRANSFER PLATE The transfer plate channels line pressure to the solenoid valve through the governor body. It also channels governor pressure from the solenoid valve to the governor circuit. It is the solenoid valve that develops the necessary governor pressure. GOVERNOR PRESSURE CURVES LOW TRANSMISSION FLUID TEMPERATURE When the transmission fluid is cold the conventional governor can delay shifts, resulting in higher than normal shift speeds and harsh shifts. The electronically controlled low temperature governor pressure curve is higher than normal to make the transmission shift at normal speeds and sooner. The PCM uses a temperature sensor in the transmission oil sump to determine when low temperature governor pressure is needed. NORMAL OPERATION Normal operation is refined through the increased computing power of the PCM and through access to data on engine operating conditions provided by the PCM that were not available with the previous stand-alone electronic module. This facilitated the development of a load adaptive shift strategy - the ability to alter the shift schedule in response to vehicle load condition. One manifestation of this capability is grade "hunting" prevention - the ability of the transmission logic to delay an upshift; on a grade if the engine does not have sufficient power to maintain speed in the higher gear. The 3-2 downshift and the potential for hunting between gears occurs with a heavily loaded vehicle or on steep grades. When hunting occurs, it is very objectionable because shifts are frequent and accompanied by large changes in noise and acceleration. WIDE OPEN THROTTLE OPERATION In wide-open throttle (WOT) mode, adaptive memory in the PCM assures that up-shifts occur at the preprogrammed optimum speed. WOT operation is determined from the throttle position sensor, which is also a part of the emission control system. The initial setting for the WOT upshift is below the optimum engine speed. As WOT shifts are repeated, the PCM learns the time required to complete the shifts by comparing the engine speed when the shifts occur to the optimum speed. After each shift, the PCM adjusts the shift point until the optimum speed is reached. The PCM also considers vehicle loading, grade and engine performance changes due to high altitude in determining when to make WOT shifts. It does this by measuring vehicle and engine acceleration and then factoring in the shift time. TRANSFER CASE LOW RANGE OPERATION On four-wheel drive vehicles operating in low range, the engine can accelerate to its peak more rapidly than in Normal range, resulting in delayed shifts and undesirable engine "flare." The low range governor pressure curve is also higher than normal to initiate upshifts sooner. The PCM compares electronic vehicle speed signal used by the speedometer to the transmission output shaft speed signal to determine when the transfer case is in low range. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Input Shaft, A/T > Component Information > Specifications Input Shaft: Specifications Input shaft end play 0.034 - 0.084 in Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Overdrive Indicator Lamp > Component Information > Locations Overdrive Indicator Lamp: Locations The Overdrive OFF Indicator (VFD) is part of the cluster electronic circuit board, and is visible through a cutout located in the lower right corner of the cluster overlay. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Overdrive Indicator Lamp > Component Information > Locations > Page 3659 Overdrive Indicator Lamp: Description and Operation OVERDRIVE OFF INDICATOR An overdrive OFF indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional overdrive automatic transmission, this indicator is electronically disabled. The overdrive OFF indicator consists of the text "O/D OFF", which appears in the lower portion of the electronic gear selector indicator Vacuum Fluorescent Display (VFD). The VFD is part of the cluster electronic circuit board, and is visible through a cutout located in the lower right corner of the cluster overlay. The dark lens of the VFD prevents the indicator from being clearly visible when it is not illuminated. The text "O/D OFF" appears in an amber color and at the same lighting level as the gear selector indicator information when it is illuminated by the instrument cluster electronic circuit board. The overdrive OFF indicator is serviced as a unit with the VFD in the instrument cluster. The overdrive OFF indicator gives an indication to the vehicle operator when the OFF position of the overdrive OFF switch has been selected, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The overdrive OFF indicator receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions; therefore, the indicator will always be OFF when the ignition switch is in any position except ON or Start. The indicator only illuminates when it is switched to ground by the instrument cluster circuitry. The instrument cluster will turn ON the overdrive OFF indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the overdrive OFF indicator is illuminated for about two seconds as a bulb test. - Overdrive OFF Lamp-ON Message - Each time the cluster receives an overdrive OFF lamp-ON message from the PCM indicating that the OFF position of the overdrive OFF switch has been selected, the overdrive OFF indicator will be illuminated. The indicator remains illuminated until the cluster receives an overdrive OFF lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the overdrive OFF indicator will be turned ON, then OFF again during the VFD portion of the test to confirm the functionality of the VFD, and again during the bulb check portion of the test to confirm the functionality of the cluster control circuitry. The PCM continually monitors the overdrive OFF switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper overdrive OFF lamp-ON and lamp-OFF messages to the instrument cluster. For further diagnosis of the overdrive OFF indicator or the instrument cluster circuitry that controls the indicator, (Refer to INSTRUMENT/CLUSTER DIAGNOSIS AND TESTING). For proper diagnosis of the overdrive control system, the PCM, the PCI data bus, or the message inputs to the instrument cluster that control the overdrive OFF indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Shift Indicator > Component Information > Service and Repair Shift Indicator: Service and Repair GEARSHIFT INDICATOR REMOVAL The following service procedures apply only to the mechanical gear selector indicator. The electronic gear selector indicator is integral to the instrument cluster and can only be serviced by replacement of the instrument cluster unit. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument cluster from the instrument panel. Fig. 13 3. Remove the two screws that secure the gear selector indicator mechanism to the back of the instrument cluster housing (Fig. 13). 4. Remove the gear selector indicator mechanism from the back of the instrument cluster housing. 5. Remove the steering column opening cover from the instrument panel. Fig. 14 6. Disengage the loop end of the gear selector indicator cable from the lever on the left side of the steering column (Fig. 14). 7. Squeeze the sides of the plastic adjuster and bracket unit to disengage the tabs that secure it to the sides of the steering column window. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Shift Indicator > Component Information > Service and Repair > Page 3663 8. Remove the gear selector indicator mechanism and cable unit from the instrument panel. INSTALLATION The following service procedures apply only to the mechanical gear selector indicator. The electronic gear selector indicator is integral to the instrument cluster and can only be serviced by replacement of the instrument cluster unit. 1. Position the gear selector indicator mechanism and cable unit to the instrument panel. 2. Squeeze the sides of the plastic adjuster and bracket unit and engage the tabs that secure it with the sides of the steering column window. 3. Engage the loop end of the gear selector indicator cable onto the lever on the left side of the steering column (Fig. 14). 4. Position the gear selector indicator mechanism onto the back of the instrument cluster housing. 5. Install and tighten the two screws that secure the gear selector indicator mechanism to the back of the instrument cluster housing. Tighten the screws to 2.2 N.m (20 in. lbs.). 6. Install the instrument cluster onto the instrument panel. 7. Check the gear selector indicator for proper calibration. If adjustment is needed, 8. Install the steering column opening cover onto the instrument panel. 9. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Temperature Warning Indicator - A/T > Component Information > Locations Temperature Warning Indicator - A/T: Locations The transmission over-temperature indicator is located in the Information Center area of the instrument cluster, to the left of center. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Temperature Warning Indicator - A/T > Component Information > Locations > Page 3667 Temperature Warning Indicator - A/T: Description and Operation A transmission over-temperature indicator lamp is standard equipment on all instrument clusters. The transmission over-temperature indicator is located in the Information Center area of the instrument cluster, to the left of center. The transmission over-temperature indicator consists of a stencilled cutout of the words "TRANS TEMP" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red lens behind the cutout in the opaque layer of the overlay causes the "TRANS TEMP" text to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by a Light Emitting Diode (LED) soldered onto the instrument cluster electronic circuit board. The transmission overtemperature indicator is serviced as a unit with the instrument cluster. The transmission over-temperature indicator gives an indication to the vehicle operator when the trans- mission fluid temperature is excessive, which may lead to accelerated transmission component wear or failure. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The transmission over-temperature indicator Light Emitting Diode (LED) receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions; therefore, the LED will always be OFF when the ignition switch is in any position except ON or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the transmission over-temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the transmission over-temperature indicator is illuminated for about two seconds as a bulb test. - Trans Over-Temp Lamp-ON Message - Each time the cluster receives a trans over-temp lamp-ON message from the PCM indicating that the transmission fluid temperature is 135 °C (275 °F) or higher, the indicator will be illuminated and a single chime tone is sounded. The lamp remains illuminated until the cluster receives a trans over-temp lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the transmission over-temperature indicator is cycled OFF and then on again by the appropriate trans over-temp messages from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition, then sends the proper messages to the instrument cluster. If the instrument cluster turns ON the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission and/or the transmission cooling system are being overloaded or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the transmission temperature sensor, the PCM, the PCI data bus, or the message inputs to the instrument cluster that control the transmission over-temperature indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Specifications Output Shaft: Specifications Output Shaft End Play 0.009 - 0.021 in Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft Bearing/Bushing, A/T > Component Information > Service and Repair > 42/44RE (A-500) 4 Speed Output Shaft Bearing/Bushing: Service and Repair 42/44RE (A-500) 4 Speed EXTENSION HOUSING BUSHING REMOVAL 1. Remove extension housing yoke seal. 2. Insert Remover 6957 into the extension housing. Tighten tool to bushing and remove bushing (Fig. 77). INSTALLATION 1. Align bushing oil hole with oil slot in extension housing. 2. Tap bushing into place with Installer 6951 and Handle C-4171. 3. Install new oil seal in housing using Seal Installer C-3995-A (Fig. 78). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft Bearing/Bushing, A/T > Component Information > Service and Repair > 42/44RE (A-500) 4 Speed > Page 3675 Output Shaft Bearing/Bushing: Service and Repair 46RE (A-518) 4 Speed REMOVAL 1. Remove extension housing yoke seal. 2. Insert Remover 6957 into the extension housing. Tighten tool to bushing and remove bushing (Fig. 84). INSTALLATION 1. Align bushing oil hole with oil slot in extension housing. 2. Tap bushing into place with Installer 6951 and Handle C-4171. 3. Install new oil seal in housing using Seal Installer C-3995-A (Fig. 85). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Overdrive Solenoid, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Locations Overdrive Indicator Lamp: Locations The Overdrive OFF Indicator (VFD) is part of the cluster electronic circuit board, and is visible through a cutout located in the lower right corner of the cluster overlay. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Locations > Page 3683 Overdrive Indicator Lamp: Description and Operation OVERDRIVE OFF INDICATOR An overdrive OFF indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional overdrive automatic transmission, this indicator is electronically disabled. The overdrive OFF indicator consists of the text "O/D OFF", which appears in the lower portion of the electronic gear selector indicator Vacuum Fluorescent Display (VFD). The VFD is part of the cluster electronic circuit board, and is visible through a cutout located in the lower right corner of the cluster overlay. The dark lens of the VFD prevents the indicator from being clearly visible when it is not illuminated. The text "O/D OFF" appears in an amber color and at the same lighting level as the gear selector indicator information when it is illuminated by the instrument cluster electronic circuit board. The overdrive OFF indicator is serviced as a unit with the VFD in the instrument cluster. The overdrive OFF indicator gives an indication to the vehicle operator when the OFF position of the overdrive OFF switch has been selected, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The overdrive OFF indicator receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions; therefore, the indicator will always be OFF when the ignition switch is in any position except ON or Start. The indicator only illuminates when it is switched to ground by the instrument cluster circuitry. The instrument cluster will turn ON the overdrive OFF indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the overdrive OFF indicator is illuminated for about two seconds as a bulb test. - Overdrive OFF Lamp-ON Message - Each time the cluster receives an overdrive OFF lamp-ON message from the PCM indicating that the OFF position of the overdrive OFF switch has been selected, the overdrive OFF indicator will be illuminated. The indicator remains illuminated until the cluster receives an overdrive OFF lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the overdrive OFF indicator will be turned ON, then OFF again during the VFD portion of the test to confirm the functionality of the VFD, and again during the bulb check portion of the test to confirm the functionality of the cluster control circuitry. The PCM continually monitors the overdrive OFF switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper overdrive OFF lamp-ON and lamp-OFF messages to the instrument cluster. For further diagnosis of the overdrive OFF indicator or the instrument cluster circuitry that controls the indicator, (Refer to INSTRUMENT/CLUSTER DIAGNOSIS AND TESTING). For proper diagnosis of the overdrive control system, the PCM, the PCI data bus, or the message inputs to the instrument cluster that control the overdrive OFF indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations > Page 3687 Overdrive Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations > Page 3688 Overdrive Switch: Description and Operation DESCRIPTION The overdrive OFF (control) switch is located in the shift lever arm (Fig. 95). The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function. OPERATION At key-on, overdrive operation is allowed. Pressing the switch once causes the overdrive OFF mode to be entered and the overdrive OFF switch lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the overdrive lamp to be turned off. The overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the control switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4 upshift. The control switch indicator light illuminates only when the overdrive switch is turned to the OFF position, or when illuminated by the transmission control module. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations > Page 3689 Overdrive Switch: Service and Repair REMOVAL 1. Using a plastic trim tool, remove the overdrive off switch retainer from the shift lever (Fig. 96). 2. Pull the switch outwards to release it from the connector in the lever (Fig. 97) INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector out of the lever just enough to grasp it. CAUTION: Be careful not to bend the pins on the overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations > Page 3690 2. Install the overdrive off switch into the connector (Fig. 98) 3. Push the overdrive off switch and wiring into the shift lever. 4. Install the overdrive off switch retainer onto the shift lever. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Service and Repair Planetary Gears: Service and Repair DISASSEMBLY 1. Remove the snap-ring holding the input annulus into the input carrier (Fig. 105). 2. Remove the input annulus from the input carrier (Fig. 105). 3. Remove the number 9 bearing from the reverse planetary carrier. Note that this planetary carrier has four pinion gears. 4. Remove the reverse planetary gear carrier (Fig. 105). 5. Remove the number 10 bearing from the input sun gear (Fig. 105). 6. Remove the input sun gear from the input carrier (Fig. 105). 7. Remove the number 11 bearing from the input carrier (Fig. 105). CLEANING Clean the planetary components in solvent and dry them with compressed air. INSPECTION Check sun gear and driving shell condition. Replace the gear if damaged or if the bushings are scored or worn. The bushings are not serviceable. Replace the driving shell if worn, cracked or damaged. Replace planetary gear sets if gears, pinion pins, or carrier are damaged in any way. Replace the annulus gears and supports if either component is worn or damaged. Replace the output shaft if the machined surfaces are scored, pitted, or damaged in any way. Also replace the shaft if the splines are damaged, or exhibits cracks at any location. ASSEMBLY 1. Clean and inspect all components. Replace any components which show evidence of excessive wear or scoring. 2. Install the number 11 bearing into the input planetary carrier with the flat side up and facing forward (Fig. 105). 3. Install the input sun gear into the input carrier (Fig. 105). 4. Install the number 10 bearing onto the rear of the reverse planetary carrier with the flat side toward the carrier (Fig. 105). 5. Install the number 9 bearing onto the front of the reverse planetary carrier with the rounded side toward the carrier and the flat side facing upward (Fig. 105). 6. Install the reverse planetary gear carrier into the input carrier (Fig. 105). 7. Install the input annulus gear into the input carrier (Fig. 105). 8. Install the snap-ring to hold the input annulus gear into the input carrier (Fig. 105). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > Customer Interest for Transmission Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts Transmission Control Module: Customer Interest A/T - 45RFE/545RFE Harsh Upshifts/Downshifts NUMBER: 18-025-01 GROUP: Vehicle Performance DATE: October 15, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-09-00, DATED SEPTEMBER 15, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. **ASTERISKS** HAVE BEEN USED TO HIGHLIGHT CHANGES. THIS BULLETIN ADDS A MODEL YEAR AND REQUIRES A REPROGRAMMING OF THE 1999 AND 2000 GRAND CHEROKEE POWERTRAIN CONTROL MODULE (PCM). SUBJECT: 45RFE **and 545RFE Shift** Quality Enhancements for the** 2-3, 4-5, and 5-4** Shifts OVERVIEW: This bulletin involves selectively erasing and reprogramming the **Transmission Control Module (TCM) with new software: '99-'01 WJ (PN 05019701AC Ver 9.3), '00 AN/DN (PN 05018454AB Ver 9.1), or '01 AN/DN (PN 56028285A1 Ver 8.4), and requires reprogramming of the Powertrain Control Module (PCM) for the 1999 and 2000 Grand Cherokees only (with calibration 99Cal20 (1999) or 00Cal17 (2000).** NOTE: THE 2001 GRAND CHEROKEE DOES NOT REQUIRE REPROGRAMMING OF THE PCM AS IT IS ALREADY AT THE CORRECT CALIBRATION LEVEL. NOTE: WHENEVER A PCM OR TCM IS REPLACED OR REPROGRAMMED, THE SOFTWARE OF THE PCM MUST BE VERIFIED AS HAVING THE LATEST REVISION LEVEL. MODELS: 2000 (AN) Dakota **2001** 2000 (DN) Durango **2001** 1999 (WJ) Grand Cherokee **2001 ** NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 4.7L ENGINE AND A 45RFE **OR 545RFE** TRANSMISSION. SYMPTOM/CONDITION: Some vehicles **may exhibit one or more of the following performance conditions **: 1. A harsh 2-3 upshift causing a powertrain clunk or shudder when accelerating. 2. **A harsh 4-5 upshift ('01 Grand Cherokee only).** 3. **A harsh 5-4 downshift ('01 Grand Cherokee only).** NOTE: THIS REVISION TO THE TCM SOFTWARE ADDRESSES THE ABOVE SHIFT QUALITY CONDITIONS FOR ALL VEHICLES AND, ADDS A FINAL GEAR RATIO TO THE **1999 AND 2000 MY** GRAND CHEROKEE TRANSMISSION ONLY. (2001 MY GRAND CHEROKEE ALREADY HAS THIS UPGRADE.) NOTE: TO MAINTAIN EMISSIONS COMPLIANCE, GRAND CHEROKEE VEHICLES THAT ARE EQUIPPED WITH A FEDERAL EMISSION SYSTEM (SALES CODE NAA) MUST HAVE THEIR PCM REPROGRAMMED. IF THE SOFTWARE LEVEL IS AT OR HIGHER THAN THOSE IN THE OVERVIEW ABOVE, OR IF THE GRAND CHEROKEE HAS A CALIFORNIA EMISSIONS SYSTEM (SALES CODE NAE), REPROGRAMMING IS NOT NECESSARY. DIAGNOSIS PROCEDURES: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRBIII(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 performing this repair. If no DTC's are present, and the above symptom has been experienced, perform the Repair Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > Customer Interest for Transmission Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts > Page 3703 Procedure. NOTE: **IF OTHER PERFORMANCE ISSUES REMAIN AFTER THE REPAIR PROCEDURE HAS BEEN PERFORMED THEY DO NOT RELATE TO THIS BULLETIN. REFER TO THE PROPER SERVICE OR DIAGNOSTIC PROCEDURES MANUAL(S) FOR FURTHER ASSISTANCE.** PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD **2093 OR HIGHER AND DRB III(R) VERSION 52.3 WILL BE IN THE DEALERSHIPS ON OCTOBER 15, 2001.)** REPAIR PROCEDURE: 1. Log onto the MDS2 (Mopar Diagnostic System). 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III(R), MDS2, AND VEHICLE ESTABLISH COMMUNICATION. 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. 3. Push the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) 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. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. 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, 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 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > Customer Interest for Transmission Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts > Page 3704 7. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 8. 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts Transmission Control Module: All Technical Service Bulletins A/T - 45RFE/545RFE Harsh Upshifts/Downshifts NUMBER: 18-025-01 GROUP: Vehicle Performance DATE: October 15, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-09-00, DATED SEPTEMBER 15, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. **ASTERISKS** HAVE BEEN USED TO HIGHLIGHT CHANGES. THIS BULLETIN ADDS A MODEL YEAR AND REQUIRES A REPROGRAMMING OF THE 1999 AND 2000 GRAND CHEROKEE POWERTRAIN CONTROL MODULE (PCM). SUBJECT: 45RFE **and 545RFE Shift** Quality Enhancements for the** 2-3, 4-5, and 5-4** Shifts OVERVIEW: This bulletin involves selectively erasing and reprogramming the **Transmission Control Module (TCM) with new software: '99-'01 WJ (PN 05019701AC Ver 9.3), '00 AN/DN (PN 05018454AB Ver 9.1), or '01 AN/DN (PN 56028285A1 Ver 8.4), and requires reprogramming of the Powertrain Control Module (PCM) for the 1999 and 2000 Grand Cherokees only (with calibration 99Cal20 (1999) or 00Cal17 (2000).** NOTE: THE 2001 GRAND CHEROKEE DOES NOT REQUIRE REPROGRAMMING OF THE PCM AS IT IS ALREADY AT THE CORRECT CALIBRATION LEVEL. NOTE: WHENEVER A PCM OR TCM IS REPLACED OR REPROGRAMMED, THE SOFTWARE OF THE PCM MUST BE VERIFIED AS HAVING THE LATEST REVISION LEVEL. MODELS: 2000 (AN) Dakota **2001** 2000 (DN) Durango **2001** 1999 (WJ) Grand Cherokee **2001 ** NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 4.7L ENGINE AND A 45RFE **OR 545RFE** TRANSMISSION. SYMPTOM/CONDITION: Some vehicles **may exhibit one or more of the following performance conditions **: 1. A harsh 2-3 upshift causing a powertrain clunk or shudder when accelerating. 2. **A harsh 4-5 upshift ('01 Grand Cherokee only).** 3. **A harsh 5-4 downshift ('01 Grand Cherokee only).** NOTE: THIS REVISION TO THE TCM SOFTWARE ADDRESSES THE ABOVE SHIFT QUALITY CONDITIONS FOR ALL VEHICLES AND, ADDS A FINAL GEAR RATIO TO THE **1999 AND 2000 MY** GRAND CHEROKEE TRANSMISSION ONLY. (2001 MY GRAND CHEROKEE ALREADY HAS THIS UPGRADE.) NOTE: TO MAINTAIN EMISSIONS COMPLIANCE, GRAND CHEROKEE VEHICLES THAT ARE EQUIPPED WITH A FEDERAL EMISSION SYSTEM (SALES CODE NAA) MUST HAVE THEIR PCM REPROGRAMMED. IF THE SOFTWARE LEVEL IS AT OR HIGHER THAN THOSE IN THE OVERVIEW ABOVE, OR IF THE GRAND CHEROKEE HAS A CALIFORNIA EMISSIONS SYSTEM (SALES CODE NAE), REPROGRAMMING IS NOT NECESSARY. DIAGNOSIS PROCEDURES: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRBIII(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 performing this repair. If no DTC's are present, and the above symptom has been experienced, perform the Repair Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts > Page 3710 Procedure. NOTE: **IF OTHER PERFORMANCE ISSUES REMAIN AFTER THE REPAIR PROCEDURE HAS BEEN PERFORMED THEY DO NOT RELATE TO THIS BULLETIN. REFER TO THE PROPER SERVICE OR DIAGNOSTIC PROCEDURES MANUAL(S) FOR FURTHER ASSISTANCE.** PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD **2093 OR HIGHER AND DRB III(R) VERSION 52.3 WILL BE IN THE DEALERSHIPS ON OCTOBER 15, 2001.)** REPAIR PROCEDURE: 1. Log onto the MDS2 (Mopar Diagnostic System). 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III(R), MDS2, AND VEHICLE ESTABLISH COMMUNICATION. 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. 3. Push the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) 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. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. 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, 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 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts > Page 3711 7. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 8. 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > Page 3712 Transmission Control Module: Locations Fig. 13 Transmission Control Module Location The Transmission Control Module (TCM) is located in the engine compartment on the right (passenger) side and is mounted to the radiator core support. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions Transmission Control Module: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3715 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3716 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3717 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3718 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3719 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3720 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3721 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3722 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3723 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3724 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3725 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3726 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3727 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3728 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3729 Transmission Control Module: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3730 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3731 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3732 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3733 Transmission Control Module: Connector Views Transmission Control Module Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3734 Transmission Control Module Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 3735 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 3736 Transmission Control Module: Description and Operation Fig. 13 Transmission Control Module Location The Transmission Control Module (TCM) is located in the engine compartment on the right (passenger) side and is mounted to the radiator core support (Fig. 13). The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hardwired to, and used specifically by the TCM. Indirect inputs originate from other components/modules, and are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - DRB Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 3737 - Transmission Temperature (to PCM) - PRNDL Position (to BCM) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with DRB scan tool) NOTE: If the TCM has been replaced, the "Quick Learn Procedure" must be performed. (Refer to ELECTRONIC CONTROL MODULES/ TRANSMISSION CONTROL MODULE - STANDARD PROCEDURE) Battery Feed A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain adaptive learn values in the TCM's RAM (Random Access Memory). When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. Clutch Volume Indexes (CVI) An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. Fig. 14 Example Of CVI Calculation By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur (Fig. 14). Gear ratios can be determined by using the DRB Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 3738 The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Clutch Volumes Certain mechanical problems within the input clutch assembly (broken return springs, out of position snap rings, excessive clutch pack clearance, improper assembly, etc.) can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following chart identifies the appropriate clutch volumes and when they are monitored/updated: Shift Schedules As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 3739 Driving Conditions As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 3740 Transmission Control Module: Service and Repair STANDARD PROCEDURES The quick learn procedure requires the use of the DRB scan tool. This program allows the electronic transmission system to recalibrate itself. This will provide the proper transmission operation. The quick learn procedure should be performed if any of the following procedures are performed: Transmission Assembly Replacement - Transmission Control Module Replacement - Solenoid Pack Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees. - The shift lever position must stay in PARK until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the DRB III indicates the procedure is complete - The calculated oil temperature must be above 60 ° and below 200 ° Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Power Distribution Center Transmission Control Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3744 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3745 Transmission Control System Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3746 Transmission Control Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3747 Transmission Control System Relay: Description and Operation DESCRIPTION The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. OPERATION When the relay is "off," no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Adapter Housing Seal Seals and Gaskets: Service and Repair Adapter Housing Seal ADAPTER HOUSING SEAL REMOVAL 1. Remove the transfer case from the transmission. 2. Using a screw mounted on a slide hammer, remove the adapter housing seal. INSTALLATION 1. Clean the adapter seal bore in the adapter housing of any residue or particles remaining from the original seal. 2. Install new oil seal in the adapter housing using Seal Installer C-3860-A (Fig. 53). A properly installed seal is flush to the face of the seal bore. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Adapter Housing Seal > Page 3752 Seals and Gaskets: Service and Repair Oil Pump Front Seal REMOVAL 1. Remove transmission from the vehicle. 2. Remove the torque converter from the transmission. 3. Using a screw mounted in a slide hammer, remove the oil pump front seal. INSTALLATION 1. Clean seal bore of the oil pump of any residue or particles from the original seal. 2. Install new oil seal in the oil pump housing using Seal Installer C-3860-A (Fig. 93). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair Fluid Pressure Sensor/Switch: Service and Repair LINE PRESSURE (LP) SENSOR REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pressure sensor (Fig. 81). 4. Remove the bolt holding the line pressure sensor to the transmission case. 5. Remove the line pressure sensor from the transmission case. INSTALLATION 1. Install the line pressure sensor into the transmission case. 2. Install the bolt to hold the line pressure sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 in. lbs.). 3. Install the wiring connector onto the line pressure sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations > Page 3760 Overdrive Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations > Page 3761 Overdrive Switch: Description and Operation DESCRIPTION The overdrive OFF (control) switch is located in the shift lever arm (Fig. 95). The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function. OPERATION At key-on, overdrive operation is allowed. Pressing the switch once causes the overdrive OFF mode to be entered and the overdrive OFF switch lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the overdrive lamp to be turned off. The overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the control switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4 upshift. The control switch indicator light illuminates only when the overdrive switch is turned to the OFF position, or when illuminated by the transmission control module. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations > Page 3762 Overdrive Switch: Service and Repair REMOVAL 1. Using a plastic trim tool, remove the overdrive off switch retainer from the shift lever (Fig. 96). 2. Pull the switch outwards to release it from the connector in the lever (Fig. 97) INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector out of the lever just enough to grasp it. CAUTION: Be careful not to bend the pins on the overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations > Page 3763 2. Install the overdrive off switch into the connector (Fig. 98) 3. Push the overdrive off switch and wiring into the shift lever. 4. Install the overdrive off switch retainer onto the shift lever. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3770 Transmission Position Switch/Sensor: Description and Operation DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has six switch contacts that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. - Supply ground to the TCM for backup lamp control in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > 42RE (A-500) 4 Speed Transmission Speed Sensor: Specifications Sensor, trans speed 20 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > 42RE (A-500) 4 Speed > Page 3775 Transmission Speed Sensor: Specifications Bolt, input speed sensor 105 in.lb Bolt, output speed sensor 105 in.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > 42RE (A-500) 4 Speed > Page 3776 Transmission Speed Sensor: Specifications Sensor, trans speed 20 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 3777 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor Input Speed Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor > Page 3780 Output Speed Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor Transmission Speed Sensor: Description and Operation Input Speed Sensor DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 3783 Transmission Speed Sensor: Description and Operation Output Speed Sensor OUTPUT SPEED SENSOR DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor Transmission Speed Sensor: Service and Repair Input Speed Sensor REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (Fig. 80). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor from the transmission case. INSTALLATION 1. Install the input speed sensor into the transmission case. 2. Install the bolt to hold the input speed sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the input speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor > Page 3786 Transmission Speed Sensor: Service and Repair Output Speed Sensor OUTPUT SPEED SENSOR REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor (Fig. 94). 4. Remove the bolt holding the output speed sensor to the transmission case. 5. Remove the output speed sensor from the transmission case. INSTALLATION 1. Install the output speed sensor into the transmission case. 2. Install the bolt to hold the output speed sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the output speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 3790 Transmission Temperature Sensor/Switch: Description and Operation DESCRIPTION The transmission temperature sensor is a thermistor that is integral to the Transmission Range Sensor (TRS). OPERATION The transmission temperature sensor is used by the TCM to sense the temperature of the fluid in the sump. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. Calculated Temperature A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Component Information > Technical Service Bulletins > Recalls for Shift Interlock: > NHTSA07V555000 > Dec > 07 > Recall 07V555000: A/T Shift Interlock Defect Shift Interlock: Recalls Recall 07V555000: A/T Shift Interlock Defect MAKE/MODELS: MODEL/BUILD YEARS: Dodge/Dakota 2001-2002 Dodge/Durango 2001-2002 Dodge/RAM Pickup 2002 Dodge/RAM Van 2001-2002 MANUFACTURER: Chrysler LLC. NHTSA CAMPAIGN ID NUMBER: 07V555000 MFR'S REPORT DATE: December 04, 2007 COMPONENT: Power Train: Automatic Transmission: Lever and Linkage: Column Shift POTENTIAL NUMBER OF UNITS AFFECTED: 576418 SUMMARY: On certain van and pickup trucks equipped with automatic transmissions, the ignition/park shift interlock system may become inoperative. This can allow the shifter to be moved out of the "PARK" position with the ignition key removed (or in the "LOCK" position). This can also allow the ignition key to be removed when the shifter has not been placed in the "PARK" position. CONSEQUENCE: Either of these conditions could allow the vehicle to roll away causing a crash without warning. REMEDY: Dealers will replace the gearshift blocker and bracket assembly free of charge. The recall is expected to begin during January 2008. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. G28. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Component Information > Technical Service Bulletins > Recalls for Shift Interlock: > G28 > Dec > 07 > Recall - A/T Ignition/Park Interlock Technical Service Bulletin # G28 Date: 071201 Recall - A/T Ignition/Park Interlock December 2007 Dealer Service Instructions for: Safety Recall G28 Ignition/Park Interlock Models 2001 - 2002 (AB) Dodge Ram Van/Wagon (AN) Dodge Dakota (DN) Dodge Durango 2002 (DR) Dodge Ram Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with an automatic transmission and a column shifter built through January 2, 2002. This recall also applies to certain late built 2002 vehicles equipped with a steering column built before January 2, 2002. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The ignition/Park interlock system on about 578,000 of the above vehicles may become inoperative. This can allow the shifter to be moved out of the "Park" position with the ignition key removed (or in the "Lock" position). This can also allow the ignition key to be removed when the shifter has not been placed in the "Park" position. Either of these conditions could allow the vehicle to roll away and cause a crash without warning. Repair The steering column gear shift blocker must be replaced. Parts Information Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Component Information > Technical Service Bulletins > Recalls for Shift Interlock: > G28 > Dec > 07 > Recall - A/T Ignition/Park Interlock > Page 3803 Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the operation number and time allowance shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Service Procedure Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Component Information > Technical Service Bulletins > Recalls for Shift Interlock: > G28 > Dec > 07 > Recall - A/T Ignition/Park Interlock > Page 3804 1. Disconnect the negative battery cable. 2. Remove the driver's side knee blocker. 3. Vehicles equipped with a tilt steering column, place the column tilt in its full down position. 4. Vehicles equipped with a tilt steering column, remove the tilt column lever handle. 5. Loosen the four (4) steering column mounting nuts to partially lower the steering column. 6. Remove the lower steering column cover retaining screws. 7. Separate and remove the upper and lower steering column covers. 8. Remove the four (4) steering column mounting nuts and lower the column. 9. Disconnect the white gear shift handle overdrive switch connector. 10. Disconnect the transmission gear shift cable from the steering column gear shift housing ball stud. 11. Using a male 25T Torx® driver, remove the three fasteners that retain the gear shift module to the steering column (Figure 1). 12. Rotate the gear shift module assembly towards the steering wheel and remove it from the steering column assembly. 13. Unclip the overdrive shift switch wiring harness from the metal spring clip on the gear shift blocker bracket. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Component Information > Technical Service Bulletins > Recalls for Shift Interlock: > G28 > Dec > 07 > Recall - A/T Ignition/Park Interlock > Page 3805 14. Pull on the gear shift lever to compress the gear shift lever spring and temporarily insert a pencil (or equivalent) between the gear shift lever and gear shift housing to release any spring tension on the gear shift blocker bracket (Figure 2). 15. Using a male 25T Torx driver, remove the gear shift lever pivot screw and associated flat and wave washers. CAUTION: Keep all of the washers in the order they were removed. 16. Remove and discard the original gear shift blocker bracket assembly from the gear shift housing. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Component Information > Technical Service Bulletins > Recalls for Shift Interlock: > G28 > Dec > 07 > Recall - A/T Ignition/Park Interlock > Page 3806 17. Clean and lightly lubricate the white plastic bushing located under the gear shift blocker bracket assembly with Lubriplate® white grease (Figure 3). 18. With the white plastic bushing in place on the gear shift lever housing, install the new gear shift blocker assembly (Figure 3). 19. Clean and lightly lubricate the black plastic washer, wave washer and steel washer with Lubriplate white grease (Figure 3). 20. Install the wave washer, black plastic washer and flat steel washer in the order shown in Figure 3 while aligning the square holes in the steel washer with the alignment tabs on the gear shift housing. 21. Install gear shift lever pivot screw and tighten to 105 in. lbs. (12 N.m) (Figure 3). 22. Pull on the gear shift lever to compress the gear shift lever spring and remove the pencil. 23. Clip the overdrive gear shift switch wiring harness into the plastic clip located on the gear shift blocker bracket. 24. Place the gear shift module assembly into position on the steering column. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Component Information > Technical Service Bulletins > Recalls for Shift Interlock: > G28 > Dec > 07 > Recall - A/T Ignition/Park Interlock > Page 3807 CAUTION: Be sure that the gear shift blocker pin is inserted into the steering column slide bracket hole (Figure 4). 25. Install the three (3) shift module assembly mounting screws and tighten them to 105 in. lbs. (12 N·m) (Figure 1). 26. Connect the transmission gear shift cable to the steering column gear shift housing ball stud. 27. Connect the white gear shift handle overdrive switch connector to the instrument panel wiring harness. 28. Install the upper and lower steering column covers. 29. Install the lower steering column cover retaining screws. 30. Install the gear shift lever boot. 31. Lift the steering column into position and install the four (4) steering column mounting nuts. Tighten the nuts to 21 ft. lbs. (28 N.m). 32. Vehicles equipped with a tilt steering column, install the tilt column lever handle. 33. Install the driver¡C■s side knee blocker. 34. Connect the negative battery cable. 35. Verify that the steering column and gear shift lever is functioning properly and that the key cannot be removed if the gear shift lever is not in the "Park" position. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Component Information > Technical Service Bulletins > Recalls for Shift Interlock: > G28 > Dec > 07 > Recall - A/T Ignition/Park Interlock > Page 3808 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock: > NHTSA07V555000 > Dec > 07 > Recall 07V555000: A/T Shift Interlock Defect Shift Interlock: All Technical Service Bulletins Recall 07V555000: A/T Shift Interlock Defect MAKE/MODELS: MODEL/BUILD YEARS: Dodge/Dakota 2001-2002 Dodge/Durango 2001-2002 Dodge/RAM Pickup 2002 Dodge/RAM Van 2001-2002 MANUFACTURER: Chrysler LLC. NHTSA CAMPAIGN ID NUMBER: 07V555000 MFR'S REPORT DATE: December 04, 2007 COMPONENT: Power Train: Automatic Transmission: Lever and Linkage: Column Shift POTENTIAL NUMBER OF UNITS AFFECTED: 576418 SUMMARY: On certain van and pickup trucks equipped with automatic transmissions, the ignition/park shift interlock system may become inoperative. This can allow the shifter to be moved out of the "PARK" position with the ignition key removed (or in the "LOCK" position). This can also allow the ignition key to be removed when the shifter has not been placed in the "PARK" position. CONSEQUENCE: Either of these conditions could allow the vehicle to roll away causing a crash without warning. REMEDY: Dealers will replace the gearshift blocker and bracket assembly free of charge. The recall is expected to begin during January 2008. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. G28. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock: > G28 > Dec > 07 > Recall - A/T Ignition/Park Interlock Technical Service Bulletin # G28 Date: 071201 Recall - A/T Ignition/Park Interlock December 2007 Dealer Service Instructions for: Safety Recall G28 Ignition/Park Interlock Models 2001 - 2002 (AB) Dodge Ram Van/Wagon (AN) Dodge Dakota (DN) Dodge Durango 2002 (DR) Dodge Ram Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with an automatic transmission and a column shifter built through January 2, 2002. This recall also applies to certain late built 2002 vehicles equipped with a steering column built before January 2, 2002. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The ignition/Park interlock system on about 578,000 of the above vehicles may become inoperative. This can allow the shifter to be moved out of the "Park" position with the ignition key removed (or in the "Lock" position). This can also allow the ignition key to be removed when the shifter has not been placed in the "Park" position. Either of these conditions could allow the vehicle to roll away and cause a crash without warning. Repair The steering column gear shift blocker must be replaced. Parts Information Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock: > G28 > Dec > 07 > Recall - A/T Ignition/Park Interlock > Page 3818 Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the operation number and time allowance shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Service Procedure Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock: > G28 > Dec > 07 > Recall - A/T Ignition/Park Interlock > Page 3819 1. Disconnect the negative battery cable. 2. Remove the driver's side knee blocker. 3. Vehicles equipped with a tilt steering column, place the column tilt in its full down position. 4. Vehicles equipped with a tilt steering column, remove the tilt column lever handle. 5. Loosen the four (4) steering column mounting nuts to partially lower the steering column. 6. Remove the lower steering column cover retaining screws. 7. Separate and remove the upper and lower steering column covers. 8. Remove the four (4) steering column mounting nuts and lower the column. 9. Disconnect the white gear shift handle overdrive switch connector. 10. Disconnect the transmission gear shift cable from the steering column gear shift housing ball stud. 11. Using a male 25T Torx® driver, remove the three fasteners that retain the gear shift module to the steering column (Figure 1). 12. Rotate the gear shift module assembly towards the steering wheel and remove it from the steering column assembly. 13. Unclip the overdrive shift switch wiring harness from the metal spring clip on the gear shift blocker bracket. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock: > G28 > Dec > 07 > Recall - A/T Ignition/Park Interlock > Page 3820 14. Pull on the gear shift lever to compress the gear shift lever spring and temporarily insert a pencil (or equivalent) between the gear shift lever and gear shift housing to release any spring tension on the gear shift blocker bracket (Figure 2). 15. Using a male 25T Torx driver, remove the gear shift lever pivot screw and associated flat and wave washers. CAUTION: Keep all of the washers in the order they were removed. 16. Remove and discard the original gear shift blocker bracket assembly from the gear shift housing. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock: > G28 > Dec > 07 > Recall - A/T Ignition/Park Interlock > Page 3821 17. Clean and lightly lubricate the white plastic bushing located under the gear shift blocker bracket assembly with Lubriplate® white grease (Figure 3). 18. With the white plastic bushing in place on the gear shift lever housing, install the new gear shift blocker assembly (Figure 3). 19. Clean and lightly lubricate the black plastic washer, wave washer and steel washer with Lubriplate white grease (Figure 3). 20. Install the wave washer, black plastic washer and flat steel washer in the order shown in Figure 3 while aligning the square holes in the steel washer with the alignment tabs on the gear shift housing. 21. Install gear shift lever pivot screw and tighten to 105 in. lbs. (12 N.m) (Figure 3). 22. Pull on the gear shift lever to compress the gear shift lever spring and remove the pencil. 23. Clip the overdrive gear shift switch wiring harness into the plastic clip located on the gear shift blocker bracket. 24. Place the gear shift module assembly into position on the steering column. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock: > G28 > Dec > 07 > Recall - A/T Ignition/Park Interlock > Page 3822 CAUTION: Be sure that the gear shift blocker pin is inserted into the steering column slide bracket hole (Figure 4). 25. Install the three (3) shift module assembly mounting screws and tighten them to 105 in. lbs. (12 N·m) (Figure 1). 26. Connect the transmission gear shift cable to the steering column gear shift housing ball stud. 27. Connect the white gear shift handle overdrive switch connector to the instrument panel wiring harness. 28. Install the upper and lower steering column covers. 29. Install the lower steering column cover retaining screws. 30. Install the gear shift lever boot. 31. Lift the steering column into position and install the four (4) steering column mounting nuts. Tighten the nuts to 21 ft. lbs. (28 N.m). 32. Vehicles equipped with a tilt steering column, install the tilt column lever handle. 33. Install the driver¡C■s side knee blocker. 34. Connect the negative battery cable. 35. Verify that the steering column and gear shift lever is functioning properly and that the key cannot be removed if the gear shift lever is not in the "Park" position. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock: > G28 > Dec > 07 > Recall - A/T Ignition/Park Interlock > Page 3823 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair Shift Solenoid: Service and Repair REMOVAL 1. Remove the valve body from the transmission (Fig. 116). 2. Remove the screws holding the transmission solenoid/TRS assembly onto the valve body (Fig. 117). 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the screws to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 5.7 Nm (50 inch lbs.). 5. Tighten the remainder of the solenoid assembly screws to 5.7 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Description and Operation Shifter A/T: Description and Operation DESCRIPTION The gear shift mechanism provides six shift positions which are: Park (P) - Reverse (R) - Neutral (N) - Drive (D) - Manual second (2) - Manual low (1) OPERATION MANUAL LOW (1) range provides first gear only. Overrun braking is also provided in this range. MANUAL SECOND (2) range provides first and second gear only. DRIVE range provides FIRST, SECOND THIRD and OVERDRIVE FOURTH gear ranges. The shift into OVERDRIVE FOURTH gear range occurs only after the transmission has completed the shift into D THIRD gear range. No further movement of the shift mechanism is required to complete the 3-4 shift. The FOURTH gear upshift occurs automatically when the overdrive selector switch is in the ON position. No upshift to FOURTH gear will occur if any of the following are true: ^ The transmission fluid temperature is below 10°C (50°F) or above 121°C (250°F). The shift to THIRD is not yet complete. Vehicle speed is too low for the 3-4 shift to occur. Battery temperature is below -5°C (23°F). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection Shift Cable: Testing and Inspection DIAGNOSIS AND TESTING - GEARSHIFT CABLE 1. The shifter lever and gate positions should be in alignment with all transmission PARK NEUTRAL, and gear detent positions. 2. Engine starts must be possible with shift lever in PARK or NEUTRAL gate positions only. Engine starts must not be possible in any other gear position. 3. With shift lever handle in: a. PARK position - Apply forward force on center of lever and remove pressure. Engine starts must be possible. b. PARK position - Apply rearward force on center- of lever and remove pressure. Engine starts must be possible. c. NEUTRAL position - Normal position. Engine starts must be possible. d. NEUTRAL position - Engine running and brakes applied, apply forward force on center of shift, lever. Transmission shall not be able to shift from neutral to reverse. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection > Page 3834 Shift Cable: Adjustments ADJUSTMENTS - GEARSHIFT CABLE Check adjustment by starting the engine in PARK and NEUTRAL. Adjustment is CORRECT if the engine starts only in these positions. Adjustment is INCORRECT if the engine starts in one but not both positions. If the engine starts in any position other than PARK or NEUTRAL, or if the engine will not start at all, the transmission range sensor may be faulty. Gearshift Adjustment Procedure 1. Shift transmission into PARK. 2. Release cable adjuster lock tab (underneath the steering column) (Fig. 63) to unlock cable. 3. Raise vehicle. 4. Disengage the cable eyelet from the transmission manual shift lever. 5. Verify transmission shift lever is in PARK detent by moving lever fully rearward. Last rearward detent is PARK position. 6. Verify positive engagement of transmission park lock by attempting to rotate propeller shaft. Shaft will not rotate when park lock is engaged. 7. Snap the cable eyelet onto the transmission manual shift lever. 8. Lower vehicle. 9. Lock shift cable by pressing cable adjuster lock tab upward until it snaps into place. 10. Check engine starting. Engine should start only in PARK and NEUTRAL Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection > Page 3835 Shift Cable: Service and Repair REMOVAL 1. Shift transmission into PARK. 2. Remove the dash panel insulation pad as necessary to access the gearshift cable bracket mounting nuts. 3. Remove nuts retaining the gearshift cable mounting bracket to the dash panel (Fig. 55) or (Fig. 56). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection > Page 3836 4. Disconnect cable at lower column lever and feed cable through dash panel opening to underside of vehicle (Fig. 57). 5. Raise vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection > Page 3837 6. Disengage cable eyelet at transmission shift lever and pull cable adjuster out of mounting bracket (Fig. 58) or (Fig. 59). Remove old cable from vehicle. INSTALLATION 1. Snap the cable into the transmission bracket so the retaining ears are engaged and snap the cable eyelet onto the manual control lever ball stud. 2. Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection > Page 3838 3. Route cable through hole in dash panel (Fig. 60) or (Fig. 61). 4. Seat the cable mounting bracket to dash panel and install retaining nuts to hold the cable housing bracket to the dash panel. 5. Tighten the nuts to 34 Nm (25 ft. lbs.). 6. Place the transmission manual shift lever in the "PARK" detent (rearmost) position and rotate prop shaft to ensure transmission is in PARK. 7. Connect shift cable to the steering column shift lever (Fig. 62) by snapping the cable retaining ears into shifter bracket and snapping the cable eyelet on the steering column ball stud. 8. Lock the shift cable adjustment by pressing the cable adjuster lock upward until it snaps into place. 9. Check for proper operation of the transmission range sensor. 10. Adjust the gearshift cable as necessary. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Temperature Warning Indicator - A/T > Component Information > Locations Temperature Warning Indicator - A/T: Locations The transmission over-temperature indicator is located in the Information Center area of the instrument cluster, to the left of center. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Temperature Warning Indicator - A/T > Component Information > Locations > Page 3842 Temperature Warning Indicator - A/T: Description and Operation A transmission over-temperature indicator lamp is standard equipment on all instrument clusters. The transmission over-temperature indicator is located in the Information Center area of the instrument cluster, to the left of center. The transmission over-temperature indicator consists of a stencilled cutout of the words "TRANS TEMP" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red lens behind the cutout in the opaque layer of the overlay causes the "TRANS TEMP" text to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by a Light Emitting Diode (LED) soldered onto the instrument cluster electronic circuit board. The transmission overtemperature indicator is serviced as a unit with the instrument cluster. The transmission over-temperature indicator gives an indication to the vehicle operator when the trans- mission fluid temperature is excessive, which may lead to accelerated transmission component wear or failure. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The transmission over-temperature indicator Light Emitting Diode (LED) receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions; therefore, the LED will always be OFF when the ignition switch is in any position except ON or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the transmission over-temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the transmission over-temperature indicator is illuminated for about two seconds as a bulb test. - Trans Over-Temp Lamp-ON Message - Each time the cluster receives a trans over-temp lamp-ON message from the PCM indicating that the transmission fluid temperature is 135 °C (275 °F) or higher, the indicator will be illuminated and a single chime tone is sounded. The lamp remains illuminated until the cluster receives a trans over-temp lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the transmission over-temperature indicator is cycled OFF and then on again by the appropriate trans over-temp messages from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition, then sends the proper messages to the instrument cluster. If the instrument cluster turns ON the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission and/or the transmission cooling system are being overloaded or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the transmission temperature sensor, the PCM, the PCI data bus, or the message inputs to the instrument cluster that control the transmission over-temperature indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Boost Valve Assembly, A/T <--> [Throttle Valve Assembly, A/T] > Pressure Boost Valve <--> [Throttle Valve, A/T] > Component Information > Locations Pressure Boost Valve: Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Boost Valve Assembly, A/T <--> [Throttle Valve Assembly, A/T] > Pressure Boost Valve <--> [Throttle Valve, A/T] > Component Information > Locations > Page 3847 Pressure Boost Valve: Service and Repair Refer to Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body, A/T/Service and Repair/46RE Automatic Transmission/Disassembly for disassembly procedure. Refer to Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body, A/T/Service and Repair/46RE Automatic Transmission/Assembly for assembly procedure. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed Throttle Valve Cable/Linkage: Description and Operation 42RE (A-500) 4 Speed DESCRIPTION Transmission throttle valve cable (Fig. 237) adjustment is extremely important to proper operation. This adjustment positions the throttle valve, which controls shift speed, quality, and part-throttle downshift sensitivity. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3852 If cable setting is too loose, early shifts and slippage between shifts may occur. If the setting is too tight, shifts may be delayed and part throttle downshifts may be very sensitive. The transmission throttle valve is operated by a cam on the throttle lever. The throttle lever is operated by an adjustable cable (Fig. 238). The cable is attached to an arm mounted on the throttle lever shaft. A retaining clip at the engine-end of the cable is removed to provide for cable adjustment. The retaining clip is then installed back onto the throttle valve cable to lock in the adjustment. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3853 Throttle Valve Cable/Linkage: Description and Operation 46RE (A-518) 4 Speed DESCRIPTION Transmission throttle valve cable (Fig. 238) adjustment is extremely important to proper operation. This adjustment positions the throttle valve, which controls shift speed, quality, and part-throttle downshift sensitivity. If cable setting is too loose, early shifts and slippage between shifts may occur. If the setting is too tight, shifts may be delayed and part throttle downshifts may be very sensitive. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3854 The transmission throttle valve is operated by a cam on the throttle lever. The throttle lever is operated by an adjustable cable (Fig. 239). The cable is attached to an arm mounted on the throttle lever shaft. A retaining clip at the engine-end of the cable is removed to provide for cable adjustment. The retaining clip is then installed back onto the throttle valve cable to lock in the adjustment. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Adjustments > 42RE (A-500) 4 Speed Throttle Valve Cable/Linkage: Adjustments 42RE (A-500) 4 Speed ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE A correctly adjusted throttle valve cable will cause the throttle lever on the transmission to move simultaneously with the throttle body lever from the idle position. Proper adjustment will allow simultaneous movement without causing the transmission throttle lever to either move ahead of, or lag behind the lever on the throttle body. ADJUSTMENT VERIFICATION 1. Turn ignition key to OFF position. 2. Remove air cleaner. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Adjustments > 42RE (A-500) 4 Speed > Page 3857 3. Verify that lever on throttle body is at curb idle position (Fig. 239). Then verify that the transmission throttle lever (Fig. 240) is also at idle (fully forward) position. 4. Slide cable off attachment stud on throttle body lever. 5. Compare position of cable end to attachment stud on throttle body lever: - Cable end and attachment stud should be aligned (or centered on one another) to within 1 mm (0.039 inch) in either direction (Fig. 241). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Adjustments > 42RE (A-500) 4 Speed > Page 3858 - If cable end and attachment stud are misaligned (off center), cable will have to be adjusted as described in Throttle Valve Cable 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. - If both levers move simultaneously from idle to half-throttle and back to idle position, adjustment is correct. - 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. ADJUSTMENT PROCEDURE 1. Turn ignition switch to OFF position. 2. Remove air cleaner if necessary. 3. Disconnect cable end from attachment stud. Carefully slide cable off stud. Do not pry or pull cable off. 4. Verify that transmission throttle lever is in fully closed position. Then be sure lever on throttle body is at curb idle position. 5. Pry the T.V, cable lock (A) into the UP position (Fig. 241). This will unlock the cable and allow for readjustment. 6. Apply just enough tension on the T.V. cable (B) to remove any slack in the cable. Pulling too tight will cause the T.V. lever on the transmission to move out of its idle position, which will result in an incorrect T.V. cable adjustment. Slide the sheath of the T.V. cable (D) back and forth until the centerlines of the T.V. cable end (B) and the throttle bell crank lever (C) are aligned within one millimeter (1mm) (Fig. 241). 7. While holding the T.V. cable in the set position push the TX cable lock (A) into the down position (Fig. 241). This will lock the present T.V cable adjustment. NOTE: Be sure that as the cable is pulled forward and centered on the throttle lever stud, the cable housing moves smoothly with the cable. Due to the angle at which the cable housing enters the spring housing, the cable housing may bind slightly and create an incorrect adjustment. 8. Reconnect the T.V. cable (B) to the throttle bellcrank lever (C). 9. Check cable adjustment. Verify transmission throttle lever and lever on throttle body move simultaneously. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Adjustments > 42RE (A-500) 4 Speed > Page 3859 Throttle Valve Cable/Linkage: Adjustments 46RE (A-518) 4 Speed TRANSMISSION THROTTLE VALVE CABLE A correctly adjusted throttle valve cable will cause the throttle lever on the transmission to move simultaneously with the throttle body lever from the idle position. Proper adjustment will allow simultaneous movement without causing the transmission throttle lever to either move ahead of, or lag behind the lever on the throttle body. ADJUSTMENT VERIFICATION 1. Turn ignition key to OFF position. 2. Remove air cleaner. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Adjustments > 42RE (A-500) 4 Speed > Page 3860 3. Verify that lever on throttle body is at curb idle position (Fig. 240). Then verify that the transmission throttle lever (Fig. 241) is also at idle (fully forward) position. 4. Slide cable off attachment stud on throttle body lever. 5. Compare position of cable end to attachment stud on throttle body lever: - Cable end and attachment stud should be aligned (or centered on one another) to within 1 mm. (0.039 inch) in either direction (Fig. 242). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Adjustments > 42RE (A-500) 4 Speed > Page 3861 - If cable end and attachment stud are misaligned (off center), cable will have to be adjusted as described in Throttle Valve Cable 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. - If both levers move simultaneously from idle to half-throttle and back to idle position, adjustment is correct. - 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. ADJUSTMENT PROCEDURE 1. Turn ignition switch to OFF position. 2. Remove air cleaner if necessary. 3. Disconnect cable end from attachment stud. Carefully slide cable off stud. Do not pry or pull cable off. 4. Verify that transmission throttle lever is in fully closed position. Then be sure lever on throttle body is at curb idle position. 5. Pry the T.V cable lock (A) into the UP position (Fig. 242). This will unlock the cable and allow for readjustment. 6. Apply just enough tension on the T.V cable (B) to remove any slack in the cable. Pulling too tight will cause the T.V. lever on the transmission to move out of its idle position, which will result in an incorrect T.V. cable adjustment. Slide the sheath of the T.V. cable (D) back and forth until the centerlines of the T.V. cable end (B) and the throttle bell crank lever (C) are aligned within one millimeter (1mm) (Fig. 242). 7. While holding the T.V cable in the set position push the TX cable lock (A) into the down position (Fig. 242). This will lock the present T.V. cable adjustment. NOTE: Be sure that as the cable is pulled forward and centered on the throttle lever stud, the cable housing moves smoothly with the cable. Due to the angle at which the cable housing enters the spring housing, the cable housing may bind slightly and create an incorrect adjustment. 8. Reconnect the T.V cable (B) to the throttle bellcrank lever (C). 9. Check cable adjustment. Verify transmission throttle lever and lever on throttle body move simultaneously. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > 42RE (A-500) 4 Speed Torque Converter: Specifications Bolt, torque converter 270 in.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > 42RE (A-500) 4 Speed > Page 3866 Torque Converter: Specifications Bolt, torque convertor 23 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > 42RE (A-500) 4 Speed > Page 3867 Torque Converter: Specifications Bolt, torque converter 270 in.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RE (A-500) 4 Speed Torque Converter: Description and Operation 42RE (A-500) 4 Speed DESCRIPTION The torque converter (Fig. 242) is a hydraulic device that couples the engine crankshaft to the transmission. The torque converter consists of an outer shell with an internal turbine, a stator, an overrunning clutch, an impeller and an electronically applied converter clutch. The converter clutch provides reduced engine speed and greater fuel economy when engaged. Clutch engagement also provides reduced transmission fluid temperatures. The torque converter hub drives the transmission oil (fluid) pump. The torque converter is a sealed, welded unit that is not repairable and is serviced as an assembly. CAUTION: The torque converter must be replaced if a transmission failure resulted in large amounts of metal or fiber contamination in the fluid. If the fluid is contaminated, flush the all transmission fluid cooler(s) and lines. IMPELLER Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3870 The impeller (Fig. 243) is an integral part of the converter housing. The impeller consists of curved blades placed radially along the inside of the housing on the transmission side of the converter. As the converter housing is rotated by the engine, so is the impeller, because they are one and the same and are the driving members of the system. TURBINE Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3871 The turbine (Fig. 244) is the output, or driven, member of the converter. The turbine is mounted within the housing opposite the impeller, but is not attached to the housing. The input shaft is inserted through the center of the impeller and splined into the turbine. The design of the turbine is similar to the impeller, except the blades of the turbine are curved in the opposite direction. STATOR Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3872 The stator assembly (Fig. 245) is mounted on a stationary shaft which is an integral part of the oil pump. The stator is located between the impeller and turbine within the torque converter case (Fig. 246). The stator contains an over-running clutch, which allows the stator to rotate only in a clockwise direction. When the stator is locked against the over-running clutch, the torque multiplication feature of the torque converter is operational. TORQUE CONVERTER CLUTCH (TCC) The TCC (Fig. 247) was installed to improve the efficiency of the torque converter that is lost to the slippage of the fluid coupling. Although the fluid coupling provides smooth, shock-free power transfer, it is natural for all fluid couplings to slip. If the impeller and turbine were mechanically locked together, a zero slippage condition could be obtained. A hydraulic piston was added to the turbine, and a friction material was added to the inside of the front cover to provide this mechanical lock-up. OPERATION Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3873 The converter impeller (Fig. 248) (driving member), which is integral to the converter housing and bolted to the engine drive plate, rotates at engine speed. The converter turbine (driven member), which reacts from fluid pressure generated by the impeller, rotates and turns the transmission input shaft. TURBINE As the fluid that was put into motion by the impeller blades strikes the blades of the turbine, some of the energy and rotational force is transferred into the turbine and the input shaft. This causes both of them (turbine and input shaft) to rotate in a clockwise direction following the impeller. As the fluid is leaving the trailing edges of the turbine's blades it continues in a "hindering" direction back toward the impeller. If the fluid is not redirected before it strikes the impeller, it will strike the impeller in such a direction that it would tend to slow it down. STATOR Torque multiplication is achieved by locking the stator's over-running clutch to its shaft (Fig. 249). Under stall conditions (the turbine is stationary), the oil leaving the turbine blades strikes the face of the stator blades and tries to rotate them in a counterclockwise direction. When this happens the overrunning clutch of the stator locks and holds the stator from rotating. With the stator locked, the oil strikes the stator blades and is redirected into a Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3874 "helping" direction before it enters the impeller. This circulation of oil from impeller to turbine, turbine to stator, and stator to impeller, can produce a maximum torque multiplication of about 2.4:1. As the turbine begins to match the speed of the impeller, the fluid that was hitting the stator in such as way as to cause it to lock-up is no longer doing so. In this condition of operation, the stator begins to free wheel and the converter acts as a fluid coupling. TORQUE CONVERTER CLUTCH (TCC) The torque converter clutch is hydraulically applied and is released when fluid is vented from the hydraulic circuit by the torque converter control (TCC) solenoid on the valve body. The torque converter clutch is controlled by the Powertrain Control Module (PCM). The torque converter clutch engages in fourth gear, and in third gear under various conditions, such as when the O/D switch is OFF, when the vehicle is cruising on a level surface after the vehicle has warmed up. The torque converter clutch will disengage momentarily when an increase in engine load is sensed by the PCM, such as when the vehicle begins to go uphill or the throttle pressure is increased. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3875 Torque Converter: Description and Operation 45RFE 4 Speed/545RFE 5 Speed DESCRIPTION The torque converter (Fig. 106) is a hydraulic device that couples the engine crankshaft to the transmission. The torque converter consists of an outer shell with an internal turbine, a stator, an overrunning clutch, an impeller and an electronically applied converter clutch. The converter clutch provides reduced engine speed and greater fuel economy when engaged. Clutch engagement also provides reduced transmission fluid temperatures. The converter clutch engages in third gear. The torque converter hub drives the transmission oil (fluid) pump and contains an O-ring seal to better control oil flow. The torque converter is a sealed, welded unit that is not repairable and is serviced as an assembly. CAUTION: The torque converter must be replaced it a transmission failure resulted in large amounts of metal or fiber contamination In the fluid. If the fluid is contaminated, flush the fluid cooler and lines. IMPELLER Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3876 The impeller (Fig. 107) is an integral part of the converter housing. The impeller consists of curved blades placed radially along the inside of the housing on the transmission side of the converter. As the converter housing is rotated by the engine, so is the impeller, because they are one and the same and are the driving members of the system. TURBINE Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3877 The turbine (Fig. 108) is the output, or driven, member of the converter. The turbine is mounted within the housing opposite the impeller, but is not attached to the housing. The input shaft is inserted through the center of the impeller and splined into the turbine. The design of the turbine is similar to the impeller, except the blades of the turbine are curved in the opposite direction. STATOR Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3878 The stator assembly (Fig. 109) is mounted on a stationary shaft which is an integral part of the oil pump. The stator is located between the impeller and turbine within the torque converter case (Fig. 110). The stator contains an over-running clutch, which allows the stator to rotate only in a clockwise direction. When the stator is locked against the over-running clutch, the torque multiplication feature of the torque converter is operational. TORQUE CONVERTER CLUTCH (TCC) The TCC (Fig. 111) was installed to improve the efficiency of the torque converter that is lost to the slippage of the fluid coupling. Although the fluid coupling provides smooth, shock-free power transfer, it is natural for all fluid couplings to slip. If the impeller and turbine were mechanically locked together, a zero slippage condition could be obtained. A hydraulic piston with friction material was added to the turbine assembly to provide this mechanical lock-up. In order to reduce heat build-up in the transmission and buffer the powertrain against torsional vibrations, the TCM can duty cycle the L/R-CC Solenoid to achieve a smooth application of the torque converter clutch. This function, referred to as Electronically Modulated Converter Clutch (EMCC) can occur at various times depending on the following variables: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3879 - Shift lever position - Current gear range - Transmission fluid temperature - Engine coolant temperature - Input speed - Throttle angle - Engine speed OPERATION The converter impeller (Fig. 112) (driving member), which is integral to the converter housing and bolted to the engine drive plate, rotates at engine speed. The converter turbine (driven member), which reacts from fluid pressure generated by the impeller, rotates and turns the transmission input shaft. TURBINE As the fluid that was put into motion by the impeller blades strikes the blades of the turbine, some of the energy and rotational force is transferred into the turbine and the input shaft. This causes both of them (turbine and input shaft) to rotate in a clockwise direction following the impeller. As the fluid is leaving the trailing edges of the turbine's blades it continues in a "hindering" direction back toward the impeller. If the fluid is not redirected before it strikes the impeller, it will strike the impeller in such a direction that it would tend to slow it down. STATOR Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3880 Torque multiplication is achieved by locking the stator's over-running clutch to its shaft (Fig. 113). Under stall conditions (the turbine is stationary), the oil leaving the turbine blades strikes the face of the stator blades and tries to rotate them in a counterclockwise direction. When this happens the over-running clutch of the stator locks and holds the stator from rotating. With the stator locked, the oil strikes the stator blades and is redirected into a "helping" direction before it enters the impeller. This circulation of oil from impeller to turbine, turbine to stator, and stator to impeller, can produce a maximum torque multiplication of about 2.4:1. As the turbine begins to match the speed of the impeller, the fluid that was hitting the stator in such as way as to cause it to lock-up is no longer doing so. In this condition of operation, the stator begins to free wheel and the converter acts as a fluid coupling. TORQUE CONVERTER CLUTCH (TCC) In a standard torque converter, the impeller and turbine are rotating at about the same speed and the stator is freewheeling, providing no torque multiplication. By applying the turbine's piston and friction material to the front cover, a total converter engagement can be obtained. The result of this engagement is a direct 1:1 mechanical link between the engine and the transmission. The clutch can be engaged in second, third, and fourth gear ranges depending on overdrive control switch position. If the overdrive control switch is in the normal ON position, the clutch will engage after the shift to fourth gear, and above approximately 72 km/h (45 mph). If the control switch is in the OFF position, the clutch will engage after the shift to third gear, at approximately 56 km/h (35 mph) at light throttle. The TCM controls the torque converter by way of internal logic software. The programming of the software provides the TCM with control over the L/R-CC Solenoid. There are four output logic states that can be applied as follows: No EMCC - Partial EMCC - Full EMCC - Gradual-to-no EMCC NO EMCC Under No EMCC conditions, the L/R Solenoid is OFF. There are several conditions that can result in NO EMCC operations. No EMCC can be initiated due to a fault in the transmission or because the TCM does not see the need for EMCC under current driving conditions. PARTIAL EMCC Partial EMCC operation modulates the L/R Solenoid (duty cycle) to obtain partial torque converter clutch application. Partial EMCC operation is maintained until Full EMCC is called for and actuated. During Partial EMCC some slip does occur. Partial EMCC will usually occur at low speeds, low load and light throttle situations. FULL EMCC During Full EMCC operation, the TCM increases the L/R Solenoid duty cycle to full ON after Partial EMCC control brings the engine speed within the desired slip range of transmission input speed relative to engine rpm. GRADUAL-TO-NO EMCC This operation is to soften the change from Full or Partial EMCC to No EMCC. This is done at mid throttle by decreasing the L/R Solenoid duty cycle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3881 Torque Converter: Description and Operation 46RE (A-518) 4 Speed DESCRIPTION The torque converter (Fig. 243) is a hydraulic device that couples the engine crankshaft to the transmission. The torque converter consists of an outer shell with an internal turbine, a stator, an overrunning clutch, an impeller and an electronically applied converter clutch. The converter clutch provides reduced engine speed and greater fuel economy when engaged. Clutch engagement also provides reduced transmission fluid temperatures. The torque converter hub drives the transmission oil (fluid) pump. The torque converter is a sealed, welded unit that is not repairable and is serviced as an assembly. CAUTION: The torque converter must be replaced if a transmission failure resulted in large amounts of metal or fiber contamination in the fluid. If the fluid is contaminated, flush the all transmission fluid cooler(s) and lines. IMPELLER Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3882 The impeller (Fig. 244) is an integral part of the converter housing. The impeller consists of curved blades placed radially along the inside of the housing on the transmission side of the converter. As the converter housing is rotated by the engine, so is the impeller, because they are one and the same and are the driving members of the system. TURBINE Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3883 The turbine (Fig. 245) is the output, or driven, member of the converter. The turbine is mounted within the housing opposite the impeller, but is not attached to the housing. The input shaft is inserted through the center of the impeller and splined into the turbine. The design of the turbine is similar to the impeller, except the blades of the turbine are curved in the opposite direction. STATOR Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3884 The stator assembly (Fig. 246) is mounted on a stationary shaft which is an integral part of the oil pump. The stator is located between the impeller and turbine within the torque converter case (Fig. 247). The stator contains an over-running clutch, which allows the stator to rotate only in a clockwise direction. When the stator is locked against the over-running clutch, the torque multiplication feature of the torque converter is operational. TORQUE CONVERTER CLUTCH (TCC) The TCC (Fig. 248) was installed to improve the efficiency of the torque converter that is lost to the slippage of the fluid coupling. Although the fluid coupling provides smooth, shock-free power transfer, it is natural for all fluid couplings to slip. If the impeller and turbine were mechanically locked together, a zero slippage condition could be obtained. A hydraulic piston was added to the turbine, and a friction material was added to the inside of the front cover to provide this mechanical lock-up. OPERATION Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3885 The converter impeller (Fig. 249) (driving member), which is integral to the converter housing and bolted to the engine drive plate, rotates at engine speed. The converter turbine (driven member), which reacts from fluid pressure generated by the impeller, rotates and turns the transmission input shaft. TURBINE As the fluid that was put into motion by the impeller blades strikes the blades of the turbine, some of the energy and rotational force is transferred into the turbine and the input shaft. This causes both of them (turbine and input shaft) to rotate in a clockwise direction following the impeller. As the fluid is leaving the trailing edges of the turbine's blades it continues in a "hindering" direction back toward the impeller. If the fluid is not redirected before it strikes the impeller, it will strike the impeller in such a direction that it would tend to slow it down. STATOR Torque multiplication is achieved by locking the stator's over-running clutch to its shaft (Fig. 250). Under stall conditions (the turbine is stationary), the oil leaving the turbine blades strikes the face of the stator blades and tries to rotate them in a counterclockwise direction. When this happens the overrunning clutch of the stator locks and holds the stator from rotating. With the stator locked, the oil strikes the stator blades and is redirected into a "helping" direction before it enters the impeller. This circulation of oil from impeller to turbine, turbine to stator, and stator to impeller, can produce a Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3886 maximum torque multiplication of about 2.4:1. As the turbine begins to match the speed of the impeller, the fluid that was hitting the stator in such as way as to cause it to lock-up is no longer doing so. In this condition of operation, the stator begins to free wheel and the converter acts as a fluid coupling. TORQUE CONVERTER CLUTCH (TCC) The torque converter clutch is hydraulically applied and is released when fluid is vented from the hydraulic circuit by the torque converter control (TCC) solenoid on the valve body. The torque converter clutch is controlled by the Powertrain Control Module (PCM). The torque converter clutch engages in fourth gear, and in third gear under various conditions, such as when the O/D switch is OFF, when the vehicle is cruising on a level surface after the vehicle has warmed up. The torque converter clutch will disengage momentarily when an increase in engine load is sensed by the PCM, such as when the vehicle begins to go uphill or the throttle pressure is increased. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > 42RE (A-500) 4 Speed Torque Converter: Service and Repair 42RE (A-500) 4 Speed REMOVAL 1. Remove transmission and torque converter from vehicle. 2. Place a suitable drain pan under the converter housing end of the transmission. CAUTION: Verity that transmission is secure on the lifting device or work surface, the center of gravity of the transmission will shift when the torque converter is removed creating an unstable condition. The torque converter is a heavy unit. Use caution when separating the torque converter from the transmission. 3. Pull the torque converter forward until the center hub clears the oil pump seal. 4. Separate the torque converter from the transmission. INSTALLATION Check converter hub and drive notches for sharp edges, burrs, scratches, or nicks. Polish the hub and notches with 320/400 grit paper or crocus cloth if necessary. The hub must be smooth to avoid damaging the pump seal at installation. 1. Lubricate oil pump seal lip with transmission fluid. 2. Place torque converter in position on transmission. CAUTION: Do not damage oil pump seal or bushing while inserting torque converter into the front of the transmission. 3. Align torque converter to oil pump seal opening. 4. Insert torque converter hub into oil pump. 5. While pushing torque converter inward, rotate converter until converter is fully seated in the oil pump gears. 6. Check converter seating with a scale and straightedge (Fig. 250). Surface of converter lugs should be 1/2 in. to rear of straightedge when converter is fully seated. 7. If necessary, temporarily secure converter with C-clamp attached to the converter housing. 8. Install the transmission in the vehicle. 9. Fill the transmission with the recommended fluid. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > 42RE (A-500) 4 Speed > Page 3889 Torque Converter: Service and Repair 45RFE 4 Speed/545RFE 5 Speed REMOVAL 1. Remove transmission and torque converter from vehicle. 2. Place a suitable drain pan under the converter housing end of the transmission. CAUTION: Verify that transmission is secure on the lifting device or work surface, the center of gravity of the transmission will shift when the torque converter is removed creating an unstable condition. The torque converter is a heavy unit. Use caution when separating the torque converter from the transmission. 3. Pull the torque converter forward until the center hub clears the oil pump seal. 4. Separate the torque converter from the transmission. INSTALLATION Check converter hub and drive flats for sharp edges, burrs, scratches, or nicks. Polish the hub and flats with 320/400 grit paper or crocus cloth if necessary. Verify that the converter hub O-ring is properly installed and is free from debris. The hub must be smooth to avoid damaging the pump seal at installation. 1. Lubricate oil pump seal lip with transmission fluid. 2. Place torque converter in position on transmission. CAUTION: Do not damage oil pump seal or converter hub O-ring while inserting torque converter into the front of the transmission. 3. Align torque converter to oil pump seal opening. 4. Insert torque converter hub into oil pump. 5. While pushing torque converter inward, rotate converter until converter is fully seated in the oil pump gears. 6. Check converter seating with a scale and straightedge (Fig. 114). Surface of converter lugs should be at least 13 mm (1/2 inch) to rear of straightedge when converter is fully seated. 7. If necessary, temporarily secure converter with C-clamp attached to the converter housing. 8. Install the transmission in the vehicle. 9. Fill the transmission with the recommended fluid. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > 42RE (A-500) 4 Speed > Page 3890 Torque Converter: Service and Repair 46RE (A-518) 4 Speed REMOVAL 1. Remove transmission and torque converter from vehicle. 2. Place a suitable drain pan under the converter housing end of the transmission. CAUTION: Verify that transmission Is secure on the lifting device or work surface, the center of gravity of the transmission will shift when the torque converter is removed creating an unstable condition. The torque converter is a heavy unit. Use caution when separating the torque converter from the transmission. 3. Pull the torque converter forward until the center hub clears the oil pump seal. 4. Separate the torque converter from the transmission. INSTALLATION Check converter hub and drive notches for sharp edges, burrs, scratches, or nicks. Polish the hub and notches with 320/400 grit paper or crocus cloth if necessary. The hub must be smooth to avoid damaging the pump seal at installation. 1. Lubricate oil pump seal lip with transmission fluid. 2. Place torque converter in position on transmission. CAUTION: Do not damage oil pump seal or bushing while inserting torque converter into the front of the transmission. 3. Align torque converter to oil pump seal opening. 4. Insert torque converter hub into oil pump. 5. While pushing torque converter inward, rotate converter until converter is fully seated in the oil pump gears. 6. Check converter seating with a scale and straightedge (Fig. 251). Surface of converter lugs should be 1/2 in. to rear of straightedge when converter is fully seated. 7. If necessary, temporarily secure converter with C-clamp attached to the converter housing. 8. Install the transmission in the vehicle. 9. Fill the transmission with the recommended fluid. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Description and Operation > 42RE (A-500) 4 Speed Torque Converter Check Valve: Description and Operation 42RE (A-500) 4 Speed DESCRIPTION The drainback valve is located in the transmission cooler outlet (pressure) line. OPERATION The valve prevents fluid from draining from the converter into the cooler and lines when the vehicle is shut down for lengthy periods. Production valves have a hose nipple at one end, while the opposite end is threaded for a flare fitting. All valves have an arrow (or similar mark) to indicate direction of flow through the valve. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Description and Operation > 42RE (A-500) 4 Speed > Page 3895 Torque Converter Check Valve: Description and Operation 46RE (A-518) 4 Speed DESCRIPTION The drainback valve is located in the transmission cooler outlet (pressure) line. OPERATION The valve prevents fluid from draining from the converter into the cooler and lines when the vehicle is shut down for lengthy periods. Production valves have a hose nipple at one end, while the opposite end is threaded for a flare fitting. All valves have an arrow (or similar mark) to indicate direction of flow through the valve. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance Torque Converter Clutch Solenoid: Customer Interest MIL ON - TCC/OD Solenoid Performance NUMBER: 21-11-00 GROUP: Transmissions EFFECTIVE DATE: October 02, 2000 SUBJECT: 46RE Transmission MIL Due To DTC P1740 - TCC or OD Solenoid Performance OVERVIEW: This bulletin involves the replacement of the transmission pressure boost valve cover plate. MODELS: 2000 - 2001 (AB) Ram Van 2000 - 2001 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 - 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 46RE TRANSMISSION BUILT BEFORE AUGUST 01, 2000 (MDH O8O1XX). SYMPTOM/CONDITION: The customer may complain of a Malfunction Indicator Lamp (MIL) illumination. Upon further analysis, it is determined that the MIL is caused by Diagnostic Trouble Code (DTC) P1740 - Torque Converter Clutch (TCC) or Overdrive Solenoid Performance. Other than the MIL, the customer may not notice any other condition with the transmission. This condition may be caused by an intermittent and momentary TCC disengagement condition. The transmission valve body pressure boost valve cover plate has been revised with a larger size orifice hole to address this condition. DIAGNOSIS: 1. Warm the transmission to normal operating temperatures. 2. Using the DRB III(R), perform a torque converter clutch (TCC) stall test. The stall test has been revised so that the TCC remains engaged for a period of four (4) seconds. NOTE: THE DRB III(R) MUST BE OPERATING AT RELEASE LEVEL 50.4 MDS2 SYSTEM CIS CD2067 OR HIGHER (AVAILABLE THE WEEK OF OCTOBER 2, 2000) IN ORDER TO PERFORM THE REVISED TORQUE CONVERTER CLUTCH STALL TEST. DO NOT USE EARLIER VERSION STALL TEST TO DETERMINE CONDITION OF THE TORQUE CONVERTER CLUTCH. 3. If the engine stalls as a result of the TCC stall test, then perform the Repair Procedure. 4. If the engine does not stall, as a result of the TCC stall test, then further diagnosis is required. The technician may want to consider the following components during their additional diagnosis: a cut or worn input shaft seals, a missing pump lock-up circuit check ball, or worn converter hub, input shaft, reaction shaft, and pump rotor. PARTS REQUIRED: REPAIR PROCEDURE: 1. Clean the pressure boost valve cover plate to remove any dirt or rust inhibitor prior to installation. The revised cover plate will have a 1.75 mm (0.069 inch) orifice hole versus a 1.22 mm (0.048 inch) orifice hole in the original plate. Make sure it is clean. 2. Using the appropriate Service Manual, Group 21 - Transmissions and Transfer Case, replace the transmission pressure boost valve cover plate p/n Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance > Page 3904 04617012. 3. Verify fluid level after warming up the transmission and cycling the shift lever several times. 4. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance Torque Converter Clutch Solenoid: All Technical Service Bulletins MIL ON - TCC/OD Solenoid Performance NUMBER: 21-11-00 GROUP: Transmissions EFFECTIVE DATE: October 02, 2000 SUBJECT: 46RE Transmission MIL Due To DTC P1740 - TCC or OD Solenoid Performance OVERVIEW: This bulletin involves the replacement of the transmission pressure boost valve cover plate. MODELS: 2000 - 2001 (AB) Ram Van 2000 - 2001 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 - 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 46RE TRANSMISSION BUILT BEFORE AUGUST 01, 2000 (MDH O8O1XX). SYMPTOM/CONDITION: The customer may complain of a Malfunction Indicator Lamp (MIL) illumination. Upon further analysis, it is determined that the MIL is caused by Diagnostic Trouble Code (DTC) P1740 - Torque Converter Clutch (TCC) or Overdrive Solenoid Performance. Other than the MIL, the customer may not notice any other condition with the transmission. This condition may be caused by an intermittent and momentary TCC disengagement condition. The transmission valve body pressure boost valve cover plate has been revised with a larger size orifice hole to address this condition. DIAGNOSIS: 1. Warm the transmission to normal operating temperatures. 2. Using the DRB III(R), perform a torque converter clutch (TCC) stall test. The stall test has been revised so that the TCC remains engaged for a period of four (4) seconds. NOTE: THE DRB III(R) MUST BE OPERATING AT RELEASE LEVEL 50.4 MDS2 SYSTEM CIS CD2067 OR HIGHER (AVAILABLE THE WEEK OF OCTOBER 2, 2000) IN ORDER TO PERFORM THE REVISED TORQUE CONVERTER CLUTCH STALL TEST. DO NOT USE EARLIER VERSION STALL TEST TO DETERMINE CONDITION OF THE TORQUE CONVERTER CLUTCH. 3. If the engine stalls as a result of the TCC stall test, then perform the Repair Procedure. 4. If the engine does not stall, as a result of the TCC stall test, then further diagnosis is required. The technician may want to consider the following components during their additional diagnosis: a cut or worn input shaft seals, a missing pump lock-up circuit check ball, or worn converter hub, input shaft, reaction shaft, and pump rotor. PARTS REQUIRED: REPAIR PROCEDURE: 1. Clean the pressure boost valve cover plate to remove any dirt or rust inhibitor prior to installation. The revised cover plate will have a 1.75 mm (0.069 inch) orifice hole versus a 1.22 mm (0.048 inch) orifice hole in the original plate. Make sure it is clean. 2. Using the appropriate Service Manual, Group 21 - Transmissions and Transfer Case, replace the transmission pressure boost valve cover plate p/n Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance > Page 3910 04617012. 3. Verify fluid level after warming up the transmission and cycling the shift lever several times. 4. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Page 3911 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Cover > Component Information > Description and Operation Torque Converter Cover: Description and Operation DESCRIPTION The structural dust cover is made of die cast aluminum and joins the lower half of the transmission bell housing to the engine bedplate. OPERATION The structural cover provides additional powertrain stiffness and reduces noise and vibration. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Cover > Component Information > Description and Operation > Page 3915 Torque Converter Cover: Service and Repair REMOVAL 1. Raise vehicle on hoist. 2. Remove the left hand exhaust pipe from exhaust manifold. 3. Loosen the right hand exhaust manifold-to-exhaust pipe retaining bolts. 4. Remove the eight bolts retaining structural cover (Fig. 86) in the sequence shown. 5. Pivot the exhaust pipe downward and remove the structural cover. INSTALLATION CAUTION: The structural cover must be installed as described in the following steps. Failure to do so will cause severe damage to the cover. 1. Position the structural cover in the vehicle. 2. Install all four bolts retaining the cover-to-engine. DO NOT tighten the bolts at this time. 3. Install the four cover-to-transmission bolts. Do NOT tighten at this time. CAUTION: The structural cover must be held tightly against both the engine and the transmission bell housing during tightening sequence. Failure to do so may cause damage to the cover. 4. Starting with the two rear cover-to-engine bolts, tighten bolts (1) (Fig. 87) to 54 Nm (40 ft. lbs.), then tighten bolts (2) (Fig. 87) and (3) to 54 Nm ( 40 ft. lbs.) in the sequence shown. 5. Install the exhaust pipe on left hand exhaust manifold. 6. Tighten exhaust manifold-to-exhaust pipe retaining bolts to 20 - 26 Nm (15 - 20 ft. lbs.). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Power Distribution Center Transmission Control Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 3919 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 3920 Transmission Control System Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 3921 Transmission Control Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 3922 Transmission Control System Relay: Description and Operation DESCRIPTION The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. OPERATION When the relay is "off," no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Description and Operation Transmission Cooler: Description and Operation DESCRIPTION CAUTION: On in-radiator type oil coolers, if transmission oil cooler is leaking, engine coolant may enter cooler, or transmission oil may enter engine cooling system. Both engine cooling system and transmission oil circuit should be drained, flushed, and inspected. There are two types of transmission oil coolers used. One type of cooler is the in-radiator type or oil to coolant type (Fig. 1). This type oil cooler is not serviceable. The second type used is a remote type auxiliary oil cooler or oil to air cooler (Fig. 2). The oil to air type cooler is located in front of the radiator, and is serviceable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Description and Operation > Page 3926 Transmission Cooler: Service and Repair FLUSHING COOLERS AND TUBES When a transmission failure has contaminated the fluid, the oil cooler(s) must be flushed. The torque converter must also be replaced. This will insure that metal particles or sludged oil are not later transferred back into the reconditioned (or replaced) transmission. The only recommended procedure for flushing coolers and lines is to use Tool 6906-B Cooler Flusher. WARNING: WEAR PROTECTIVE EYE WEAR THAT MEETS THE REQUIREMENTS OF OSHA AND ANSI Z87.1-1968. WEAR STANDARD INDUSTRIAL RUBBER GLOVES. KEEP LIGHTED CIGARETTES, SPARKS, FLAMES, AND OTHER IGNITION SOURCES AWAY FROM THE AREA TO PREVENT THE IGNITION OF COMBUSTIBLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE EXTINGUISHER IN THE AREA WHERE THE FLUSHER WILL BE USED. KEEP THE AREA WELL VENTILATED. DO NOT LET FLUSHING SOLVENT COME IN CONTACT WITH YOUR EYES OR SKIN: IF EYE CONTAMINATION OCCURS, FLUSH EYES WITH WATER FOR 15 TO 20 SECONDS. REMOVE CONTAMINATED CLOTHING AND WASH AFFECTED SKIN WITH SOAP AND WATER. SEEK MEDICAL ATTENTION. 1. Remove cover plate filler plug on Tool 6906-B. Fill reservoir 1/2 to 3/4 full of fresh flushing solution. Flushing solvents are petroleum based solutions generally used to clean automatic transmission components. DO NOT use solvents containing acids, water, gasoline, or any other corrosive liquids. 2. Reinstall filler plug on Tool 6906-B. 3. Verify pump power switch is turned OFF. Connect red alligator clip to positive (+) battery post. Connect black W alligator clip to a good ground. 4. Disconnect the cooler lines at the transmission. NOTE: When flushing transmission cooler and lines, ALWAYS reverse flush. NOTE: The converter drainback valve must be removed and an appropriate replacement hose installed to bridge the space between the transmission cooler line and the cooler fitting. Failure to remove the drainback valve will prevent reverse flushing the system. A suitable replacement hose can be found in the adapter kit supplied with the flushing tool. 5. Connect the BLUE pressure line to the OUTLET (From) cooler line. 6. Connect the CLEAR return line to the INLET (To) cooler line 7. Turn pump ON for two to three minutes to flush cooler(s) and lines. 8. Turn pump OFF. 9. Disconnect CLEAR suction line from reservoir at cover plate. Disconnect CLEAR return line at cover plate, and place it in a drain pan. 10. Turn pump ON for 30 seconds to purge flushing solution from cooler and lines. Turn pump OFF. 11. Place CLEAR suction line into a one quart container of Mopar ATF +4, type 9602, Automatic Transmission Fluid. 12. Turn pump ON until all transmission fluid is removed from the one quart container and lines. This purges any residual cleaning solvent from the transmission cooler and lines. Turn pump OFF. 13. Disconnect alligator clips from battery. Reconnect flusher lines to cover plate, and remove flushing adapters from cooler lines. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3933 Transmission Position Switch/Sensor: Description and Operation DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has six switch contacts that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. - Supply ground to the TCM for backup lamp control in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications > 42RE (A-500) 4 Speed Transmission Speed Sensor: Specifications Sensor, trans speed 20 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications > 42RE (A-500) 4 Speed > Page 3941 Transmission Speed Sensor: Specifications Bolt, input speed sensor 105 in.lb Bolt, output speed sensor 105 in.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications > 42RE (A-500) 4 Speed > Page 3942 Transmission Speed Sensor: Specifications Sensor, trans speed 20 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 3943 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor Input Speed Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor > Page 3946 Output Speed Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor Transmission Speed Sensor: Description and Operation Input Speed Sensor DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 3949 Transmission Speed Sensor: Description and Operation Output Speed Sensor OUTPUT SPEED SENSOR DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor Transmission Speed Sensor: Service and Repair Input Speed Sensor REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (Fig. 80). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor from the transmission case. INSTALLATION 1. Install the input speed sensor into the transmission case. 2. Install the bolt to hold the input speed sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the input speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor > Page 3952 Transmission Speed Sensor: Service and Repair Output Speed Sensor OUTPUT SPEED SENSOR REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor (Fig. 94). 4. Remove the bolt holding the output speed sensor to the transmission case. 5. Remove the output speed sensor from the transmission case. INSTALLATION 1. Install the output speed sensor into the transmission case. 2. Install the bolt to hold the output speed sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the output speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 3956 Transmission Temperature Sensor/Switch: Description and Operation DESCRIPTION The transmission temperature sensor is a thermistor that is integral to the Transmission Range Sensor (TRS). OPERATION The transmission temperature sensor is used by the TCM to sense the temperature of the fluid in the sump. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. Calculated Temperature A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance Valve Body: Customer Interest MIL ON - TCC/OD Solenoid Performance NUMBER: 21-11-00 GROUP: Transmissions EFFECTIVE DATE: October 02, 2000 SUBJECT: 46RE Transmission MIL Due To DTC P1740 - TCC or OD Solenoid Performance OVERVIEW: This bulletin involves the replacement of the transmission pressure boost valve cover plate. MODELS: 2000 - 2001 (AB) Ram Van 2000 - 2001 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 - 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 46RE TRANSMISSION BUILT BEFORE AUGUST 01, 2000 (MDH O8O1XX). SYMPTOM/CONDITION: The customer may complain of a Malfunction Indicator Lamp (MIL) illumination. Upon further analysis, it is determined that the MIL is caused by Diagnostic Trouble Code (DTC) P1740 - Torque Converter Clutch (TCC) or Overdrive Solenoid Performance. Other than the MIL, the customer may not notice any other condition with the transmission. This condition may be caused by an intermittent and momentary TCC disengagement condition. The transmission valve body pressure boost valve cover plate has been revised with a larger size orifice hole to address this condition. DIAGNOSIS: 1. Warm the transmission to normal operating temperatures. 2. Using the DRB III(R), perform a torque converter clutch (TCC) stall test. The stall test has been revised so that the TCC remains engaged for a period of four (4) seconds. NOTE: THE DRB III(R) MUST BE OPERATING AT RELEASE LEVEL 50.4 MDS2 SYSTEM CIS CD2067 OR HIGHER (AVAILABLE THE WEEK OF OCTOBER 2, 2000) IN ORDER TO PERFORM THE REVISED TORQUE CONVERTER CLUTCH STALL TEST. DO NOT USE EARLIER VERSION STALL TEST TO DETERMINE CONDITION OF THE TORQUE CONVERTER CLUTCH. 3. If the engine stalls as a result of the TCC stall test, then perform the Repair Procedure. 4. If the engine does not stall, as a result of the TCC stall test, then further diagnosis is required. The technician may want to consider the following components during their additional diagnosis: a cut or worn input shaft seals, a missing pump lock-up circuit check ball, or worn converter hub, input shaft, reaction shaft, and pump rotor. PARTS REQUIRED: REPAIR PROCEDURE: 1. Clean the pressure boost valve cover plate to remove any dirt or rust inhibitor prior to installation. The revised cover plate will have a 1.75 mm (0.069 inch) orifice hole versus a 1.22 mm (0.048 inch) orifice hole in the original plate. Make sure it is clean. 2. Using the appropriate Service Manual, Group 21 - Transmissions and Transfer Case, replace the transmission pressure boost valve cover plate p/n Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance > Page 3965 04617012. 3. Verify fluid level after warming up the transmission and cycling the shift lever several times. 4. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance Valve Body: All Technical Service Bulletins MIL ON - TCC/OD Solenoid Performance NUMBER: 21-11-00 GROUP: Transmissions EFFECTIVE DATE: October 02, 2000 SUBJECT: 46RE Transmission MIL Due To DTC P1740 - TCC or OD Solenoid Performance OVERVIEW: This bulletin involves the replacement of the transmission pressure boost valve cover plate. MODELS: 2000 - 2001 (AB) Ram Van 2000 - 2001 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 - 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 46RE TRANSMISSION BUILT BEFORE AUGUST 01, 2000 (MDH O8O1XX). SYMPTOM/CONDITION: The customer may complain of a Malfunction Indicator Lamp (MIL) illumination. Upon further analysis, it is determined that the MIL is caused by Diagnostic Trouble Code (DTC) P1740 - Torque Converter Clutch (TCC) or Overdrive Solenoid Performance. Other than the MIL, the customer may not notice any other condition with the transmission. This condition may be caused by an intermittent and momentary TCC disengagement condition. The transmission valve body pressure boost valve cover plate has been revised with a larger size orifice hole to address this condition. DIAGNOSIS: 1. Warm the transmission to normal operating temperatures. 2. Using the DRB III(R), perform a torque converter clutch (TCC) stall test. The stall test has been revised so that the TCC remains engaged for a period of four (4) seconds. NOTE: THE DRB III(R) MUST BE OPERATING AT RELEASE LEVEL 50.4 MDS2 SYSTEM CIS CD2067 OR HIGHER (AVAILABLE THE WEEK OF OCTOBER 2, 2000) IN ORDER TO PERFORM THE REVISED TORQUE CONVERTER CLUTCH STALL TEST. DO NOT USE EARLIER VERSION STALL TEST TO DETERMINE CONDITION OF THE TORQUE CONVERTER CLUTCH. 3. If the engine stalls as a result of the TCC stall test, then perform the Repair Procedure. 4. If the engine does not stall, as a result of the TCC stall test, then further diagnosis is required. The technician may want to consider the following components during their additional diagnosis: a cut or worn input shaft seals, a missing pump lock-up circuit check ball, or worn converter hub, input shaft, reaction shaft, and pump rotor. PARTS REQUIRED: REPAIR PROCEDURE: 1. Clean the pressure boost valve cover plate to remove any dirt or rust inhibitor prior to installation. The revised cover plate will have a 1.75 mm (0.069 inch) orifice hole versus a 1.22 mm (0.048 inch) orifice hole in the original plate. Make sure it is clean. 2. Using the appropriate Service Manual, Group 21 - Transmissions and Transfer Case, replace the transmission pressure boost valve cover plate p/n Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance > Page 3971 04617012. 3. Verify fluid level after warming up the transmission and cycling the shift lever several times. 4. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 3972 Valve Body: Specifications Bolt, Valve body to Case 105 in.lb Screw, Valve body to Transfer Plate 50 in.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > Solenoid Body Valve Body: Description and Operation Solenoid Body Transmission Solenoid/TRS Assembly TRANSMISSION SOLENOID/TRS ASSEMBLY DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly (Fig. 115). The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > Solenoid Body > Page 3975 The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, LTD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following chart: L/R is closed if output speed is below 100 rpm in Drive and Manual 2. L/R is open in Manual 1. A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Solenoid Switch Valve SOLENOID SWITCH VALVE DESCRIPTION The Solenoid Switch Valve (SSV) is located in the valve body and controls the direction of the transmission fluid when the L/R-TCC solenoid is energized. OPERATION The Solenoid Switch Valve controls line pressure from the LR-TCC solenoid. In 1st gear, the SSV will be in the downshifted position, thus directing fluid to the L/R clutch circuit. In 2nd, 3rd, and 4th, the solenoid switch valve will be in the upshifted position and directs the fluid into the torque converter clutch (TCC) circuit. When shifting into 1st gear, a special hydraulic sequence is performed to ensure SSV movement into the downshifted position. The L/R pressure switch is monitored to confirm SSV movement. If the movement is not confirmed (the L/R pressure switch does not close), 2nd gear is substituted for 1st. A DTC will be set after three unsuccessful attempts are made to get into 1st gear in one given key start. Solenoids SOLENOIDS DESCRIPTION The typical electrical solenoid used in automotive applications is a linear actuator. It is a device that produces motion in a straight line. This straight line motion can be either forward or backward in direction, and short or long distance. A solenoid is an electromechanical device that uses a magnetic force to perform work. It consists of a coil of wire, wrapped around a magnetic core made from steel or iron, and a spring loaded, movable plunger, which performs the work, or straight line motion. The solenoids used in transmission applications are attached to valves which can be classified as normally open or normally closed. The normally open solenoid valve is defined as a valve which allows hydraulic flow when no current or voltage is applied to the solenoid. The normally closed solenoid valve is defined as a valve which does not allow hydraulic flow when no current or voltage is applied to the solenoid. These valves perform hydraulic control functions for the transmission and must therefore be durable and tolerant of dirt particles. For these reasons, the valves have hardened steel poppets and ball valves. The solenoids operate the valves directly, which means that the solenoids must have very high outputs to close the valves against the sizable flow areas and line pressures found in current transmissions. Fast response time is also necessary to ensure accurate control of the transmission. The strength of the magnetic field is the primary force that determines the speed of operation in a particular solenoid design. A stronger magnetic field will cause the plunger to move at a greater speed than a weaker one. There are basically two ways to increase the force of the magnetic field: Increase the amount of current applied to the coil or - Increase the number of turns of wire in the coil. The most common practice is to increase the number of turns by using thin wire that can completely fill the available space within the solenoid housing. The strength of the spring and the length of the plunger also contribute to the response speed possible by a particular solenoid design. A solenoid can also be described by the method by which it is controlled. Some of the possibilities include variable force, pulse-width modulated, constant ON, or duty cycle. The variable force and pulsewidth modulated versions utilize similar methods to control the current flow through the solenoid to position the solenoid plunger at a desired position somewhere between full ON and full OFF. The constant ON and duty cycled versions control the voltage across the solenoid to allow either full flow or no flow through the solenoid's valve. OPERATION Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > Solenoid Body > Page 3976 When an electrical current is applied to the solenoid coil, a magnetic field is created which produces an attraction to the plunger, causing the plunger to move and work against the spring pressure and the load applied by the fluid the valve is controlling. The plunger is normally directly attached to the valve which it is to operate. When the current is removed from the coil, the attraction is removed and the plunger will return to its original position due to spring pressure. The plunger is made of a conductive material and accomplishes this movement by providing a path for the magnetic field to flow. By keeping the air gap between the plunger and the coil to the minimum necessary to allow free movement of the plunger, the magnetic field is maximized. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > Solenoid Body > Page 3977 Valve Body: Description and Operation Valve Body DESCRIPTION The valve body consists of a cast aluminum valve body, a separator plate, and a transfer plate. The valve body contains valves and check balls that control fluid delivery to the torque converter clutch, bands, and frictional clutches. The valve body contains the following components (Fig. 118) and (Fig. 119): Solenoid switch valve - Manual valve - Low/reverse switch valve - 5 Accumulators - 7 check balls OPERATION Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > Solenoid Body > Page 3978 NOTE: Refer to the Hydraulic Schematics for a visual aid in determining valve location, operation and design. SOLENOID SWITCH VALVE The Solenoid Switch Valve (SSV) controls the direction of the transmission fluid when the L/R-TCC solenoid is energized. The Solenoid Switch Valve controls line pressure from the LR-TCC solenoid. In 1st gear, the SSV will be in the downshifted position, thus directing fluid to the 1JR clutch circuit. In 2nd, 3rd, and 4th gears, the solenoid switch valve will be in the upshifted position and directs the fluid into the torque converter clutch (TCC) circuit. When shifting into 1st gear, a special hydraulic sequence is performed to ensure SSV movement into the downshifted position. The L/R pressure switch is monitored to confirm SSV movement. If the movement is not confirmed (the L/R pressure switch does not close), 2nd gear is substituted for 1st. A DTC will be set after three unsuccessful attempts are made to get into 1st gear in one given key start. MANUAL VALVE The manual valve is a relay valve. The purpose of the manual valve is to direct fluid to the correct circuit needed for a specific gear or driving range. The manual valve, as the name implies, is manually operated by the driver with a lever located on the top of the valve body. The valve is connected mechanically by a cable to the gearshift mechanism. The valve is held in each of its positions by a roller detent spring (Fig. 120) that engages the "roostercomb" of the TRS selector plate. LOW/REVERSE SWITCH VALVE The low/reverse switch valve allows the low/reverse clutch to be operated by either the LR/CC solenoid or the MS solenoid. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Removal REMOVAL 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. 1. Shift transmission into PARK. 2. Raise vehicle. 3. Disconnect wires at the solenoid and pressure switch assembly connector. 4. Position drain pan under transmission oil pan. 5. Remove transmission oil pan. 6. Remove the primary oil filter from valve body. (Fig. 121). 7. Remove bolts attaching valve body to transmission case (Fig. 122). 8. Lower the valve body and work the electrical connector out of transmission case. 9. Separate the valve body from the transmission. Installation INSTALLATION Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3981 1. Check condition of seals on valve body and the solenoid and pressure switch assembly. Replace seals if cut or worn. 2. Place TRS selector plate in the PARK position. 3. Place the transmission in the PARK position. 4. Lubricate seal on the solenoid and pressure switch assembly connector with petroleum jelly 5. Position valve body in transmission and align the manual lever on the valve body to the pin on the transmission manual shift lever. 6. Seat valve body in case and install one or two bolts to hold valve body in place. 7. Tighten valve body bolts alternately and evenly to 12 Nm (105 inch lbs.) torque. 8. Install new fluid filter on valve body. Tighten filter screws to 4.5 Nm (40 inch lbs.) torque. 9. Connect the solenoid and pressure switch assembly connector. 10. Install oil pan. Tighten pan bolts to 12 Nm (105 inch lbs.) torque. 11. Lower vehicle and fill transmission with Mopar(R) ATF +4, type 9602, fluid. 12. Check and adjust gearshift cable, if necessary. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3982 Valve Body: Service and Repair Disassemble & Assemble Disassembly DISASSEMBLY 1. Remove the screws holding the solenoid and pressure switch assembly to the valve body (Fig. 123). Do not remove the screws on the top of the solenoid and pressure switch assembly. 2. Separate the solenoid and pressure switch assembly from the valve body. 3. Remove the screw holding the detent spring (Fig. 124) onto the valve body. 4. Remove the detent spring from the valve body. 5. Remove the TRS selector plate from the valve body and the manual valve. 6. Remove the clutch passage seals from the valve body, if necessary. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3983 7. Remove the screws holding the accumulator cover onto the valve body (Fig. 125). 8. Remove the accumulator springs and pistons from the valve body. Note which accumulator piston and spring belong in each location. 9. Place the valve body on the bench with the transfer plate upward. NOTE: The valve body contains seven check balls. The transfer plate must be placed upward to prevent losing the check balls when the transfer plate is removed from the valve body. 10. Remove the screws holding the valve body to the valve body transfer plate. 11. Remove the transfer plate from the valve body. Note the location of all check balls (Fig. 126). 12. Remove the check balls from the valve body. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3984 13. Remove the retainers securing the solenoid switch valve, manual valve, and the low/reverse switch valve into the valve body and remove the associated valve and spring. Tag each valve and spring combination with location information to aid in assembly. (Fig. 127) Assembly ASSEMBLY 1. Lubricate valves, springs, and the housing valve bores with clean transmission fluid. 2. Install solenoid switch valve, manual valve, and the low/reverse switch valve into the valve body. 3. Install the retainers to hold each valve into the valve body. 4. Install the valve body check balls into their proper locations. 5. Position the transfer plate onto the valve body. 6. Install the screws to hold the transfer plate to the valve body. Tighten the screws to 5.6 Nm (50 inch lbs.). 7. Install the accumulator pistons and springs into the valve body in the location from which they were removed. Note that all accumulators except the overdrive have two springs. The overdrive accumulator piston has only one spring. 8. Position the accumulator cover onto the valve body. 9. Install the screws to hold the accumulator cover onto the valve body. Tighten the screws to 4.5 Nm (40 inch lbs.). 10. Install the TRS selector plate onto the valve body and the manual valve. 11. Install the solenoid and pressure switch assembly onto the valve body. 12. Install the screws to hold the solenoid and pressure switch assembly onto the valve body. Tighten the screws to 5.7 Nm (50 inch lbs.). Tighten the screws adjacent to the arrows cast into the bottom of the transfer plate first. 13. Position the detent spring onto the valve body. 14. Install the screw to hold the detent spring onto the valve body. Tighten the screw to 4.5 Nm (40 inch lbs.). 15. Install new clutch passage seals onto the valve body, if necessary Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3985 Valve Body: Service and Repair Cleaning and Inspection CLEANING 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. (Fig. 128) Do not immerse any of the electrical components in cleaning solution. Clean the electrical components 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. INSPECTION 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3986 Inspect the valves and plugs (Fig. 129) 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. 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. Inspect all the accumulator 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 accumulator springs. The springs must be free of distortion, warpage or broken coils. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3987 Inspect all the fluid seals on the valve body (Fig. 130). Replace any seals that are cracked, distorted, or damaged in any way. These seals pass fluid pressure directly to the clutches. Any pressure leak at these points, may cause transmission performance problems. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications DIFFERENTIAL FLUID CAPACITY C205F .................................................................................................................................................. .................................................... 1.66Liters (3.5 pts) 8 1/4 AA ............................................................................................................................................... ................................................... 2.22Liters (4.7 pts) With Trac-Lok include 5.0 oz of friction modifier 9 1/4 ..................................................................................................................................................... .................................................... 2.32Liters (4.9 pts) With Trac-Lok include 5.0 oz of friction modifier Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 3993 Fluid - Differential: Fluid Type Specifications Rear Differential 8 1/4" ................................................................................................................................................... ......................................... Thermally Stable 80W-90 9 1/4" ................................................................ ............................................................................................................................ Thermally Stable 75W-90 Note: Vehicles equipped with Trac-Lok limited slip differential requires use of friction modifier. Front Differential Thermally Stable 80W-90. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Page 3994 Fluid - Differential: Service Precautions DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 Pinion Gear: Service and Repair Rear Axle - 8 1/4 PINION GEAR/RING GEAR/ TONE RING REMOVAL NOTE: The ring gear and pinion are serviced in a matched set. Never replace one gear without replacing the other. 1. Remove differential from the axle housing. 2. Mark the companion flange and propeller shaft for installation alignment. 3. Disconnect propeller shaft from the companion flange and tie propeller shaft to underbody. 4. Place differential case in a suitable vise with soft metal jaw protectors. (Fig. 46). 5. Remove ring gear bolts from the differential case. 6. Drive ring gear off the differential case with a rawhide hammer (Fig. 46). 7. Install bolts into two of the threaded holes in the companion flange 1800 apart. 8. Position Holder 6719 against the companion Range and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so the Holder 6719 is held to the flange. 9. Hold companion flange with Holder 6719 and remove companion flange nut and washer. 10. Remove the companion flange with Remover C-452 (Fig. 47). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 > Page 3999 11. Remove pinion from housing (Fig. 48). 12. Remove pinion seal with a pry tool or slide-hammer mounted screw. 13. Remove oil slinger if equipped and front pinion bearing. 14. Remove front pinion bearing cup with Remover C-4345 and Handle C-4171 (Fig. 49). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 > Page 4000 15. Remove the rear bearing cup from housing (Fig. 50) with Remover C-4307 and Handle C-4171. 16. Remove collapsible preload spacer (Fig. 51). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 > Page 4001 17. Remove rear bearing from pinion (Fig. 52) with Puller/Press C-293-PA and Adapters C-293-47. 18. Remove depth shims from the pinion shaft and record shim thickness. INSTALLATION NOTE: The ring gear and pinion are serviced in a matched set. Do not replace the pinion without replacing the ring gear. If ring and pinion gears or bearings are replaced, Refer to Adjustments for Pinion Gear Depth Setting. 1. Apply Mopar(R) Door Ease or stick lubricant to outside surface of bearing cup. 2. Install rear pinion bearing cup (Fig. 53) with Installer C-4308 and Driver Handle C-4171 and verify cup is seated. 3. Apply Mopar(R) Door Ease or stick lubricant to outside surface of bearing cup. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 > Page 4002 4. Install front pinion bearing cup (Fig. 54) with Installer D-130 and Handle C-4171 and verify cup is seated. 5. Install front pinion bearing and oil slinger if equipped. 6. Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with Installer C-4076-B and Handle C-4735-1 (Fig. 55). 7. Place the proper thickness depth shim on the pinion shaft. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 > Page 4003 8. Install the rear bearing and slinger if equipped, on the pinion (Fig. 56) with Installer 6448 and a press. 9. Install a new collapsible preload spacer on pinion shaft and install the pinion into the housing (Fig. 57). 10. Install companion flange with Installer C-3718 and Holder 6719. 11. Install bolts into two of the threaded holes in the companion flange 180° apart. 12. Position Holder 6719 against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so the Holder 6719 is held to the flange. 13. Install the companion flange washer and a new nut on the pinion and tighten the pinion nut until there is zero bearing end-play. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 > Page 4004 14. Tighten the nut to 285 Nm (210 ft. lbs.) (Fig. 58). 15. 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 (Fig. 59). 16. Check bearing rotating torque with an inch pound torque wrench (Fig. 59). The torque necessary to rotate the pinion should be: - Original Bearings: 1 to 3 Nm (10 to 20 inch lbs.). - New Bearings: 2 to 5 Nm (15 to 35 inch lbs.). 17. Position exciter ring on differential case. 18. Using a brass drift, slowly and evenly tap the exciter ring into position. 19. Position ring gear on the differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment. 20. Invert the differential case in the vise. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 > Page 4005 21. Install new ring gear bolts and alternately tighten to 102 Nm (75 ft. lbs.) (Fig. 60). CAUTION: Do not reuse the bolts that held the ring gear to the differential case. The bolts can fracture causing extensive damage. 22. Install differential in housing and verify gear mesh and contact pattern. 23. Install differential cover and fill with gear lubricant. 24. Install propeller shaft with reference marks aligned. 25. Remove support and lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 > Page 4006 Pinion Gear: Service and Repair Rear Axle - 9 1/4 PINION GEAR/RING GEAR/ TONE RING REMOVAL NOTE: The ring gear and pinion are serviced in a matched set. Never replace one gear without replacing the other. 1. Raise and support vehicle. 2. Remove wheel and tire assemblies. 3. Mark companion flange and propeller shaft for installation reference. 4. Disconnect propeller shaft from the companion flange and tie propeller shaft to underbody. 5. Remove axle shafts. 6. Remove differential from the differential housing. 7. Place differential case in a vise with soft metal jaw protectors. (Fig. 46). 8. Remove ring gear bolts from the differential case. 9. Drive ring gear off the differential case with a rawhide hammer (Fig. 46). 10. Install bolts into two of the threaded holes in the companion flange 180" apart. 11. Position Holder 6719 against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so the Holder 6719 is held to the flange. 12. Use Holder 6719 to hold companion flange and remove the companion flange nut and washer. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 > Page 4007 13. Remove the companion flange from the pinion with Remover C-452 (Fig. 47). 14. Remove the pinion from housing (Fig. 48). 15. Remove pinion seal with a pry tool or slide-hammer mounted screw. 16. Remove oil slinger if equipped and front pinion bearing. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 > Page 4008 17. Remove front pinion bearing cup with Remover C-4345 and Handle C-4171 (Fig. 49). 18. Remove the rear bearing cup from housing (Fig. 50) with Remover C-4307 and Handle C-4171. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 > Page 4009 19. Remove the collapsible preload spacer (Fig. 51). 20. Remove rear bearing from the pinion (Fig. 52) with Puller/Press C-293-PA and Adapters C-293-47. 21. Remove depth shims from the pinion shaft and record shim thickness. INSTALLATION NOTE: The ring gear and pinion are serviced in a matched set. Do not replace the pinion without replacing the ring gear. If ring and pinion gears or bearings are replaced, Refer to Adjustments for Pinion Gear Depth Setting. 1. Apply Mopar(R) Door Ease or stick lubricant to outside surface of bearing cup. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 > Page 4010 2. Install rear pinion bearing cup (Fig. 53) with Installer C-4308 and Driver Handle C-4171 and verify cup is seated. 3. Apply Mopar(R) Door Ease or stick lubricant to outside surface of bearing cup. 4. Install front pinion bearing cup (Fig. 54) with Installer D-130 and Handle C-4171 and verify cup is seated. 5. Install front pinion bearing. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 > Page 4011 6. Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with Installer C-4076-B and Handle C-4735-1 (Fig. 55). 7. Place the proper thickness depth shim on the pinion shaft. 8. Install the rear bearing on the pinion (Fig. 56) with Installer 6448 and a press. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 > Page 4012 9. Install a new collapsible preload spacer on pinion shaft and install the pinion into the housing (Fig. 57). 10. Install companion flange with Installer C-3718 and Holder 6719. 11. Install bolts into two of the threaded holes in the companion flange 180° apart. 12. Position Holder 6719 against the companion flange and install a bolt and washer into one of the remaining threaded holes. 'Tighten the bolts so the Holder 6719 is held to the flange. 13. Install the companion flange washer and a new nut on the pinion and tighten the pinion nut until there is zero bearing end-play. 14. Tighten the nut to 285 Nm (210 ft. lbs.) (Fig. 58). CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 > Page 4013 15. 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 (Fig. 59). 16. Check bearing rotating torque with an inch pound torque wrench (Fig. 59). The torque necessary to rotate the pinion should be: - Original Bearings: 1 to 3 Nm (10 to 20 inch lbs.). - New Bearings: 2 to 5 Nm (15 to 35 inch lbs.). 17. Position exciter ring on differential case. 18. Using a brass drift, slowly and evenly tap the exciter ring into position. 19. Position ring gear on the differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment. 20. Invert the differential case in the vise. 21. Install new ring gear bolts and alternately tighten to 156 Nm (115 ft. lbs.) (Fig. 60). CAUTION: Do not reuse the bolts that held the ring gear to the differential case. The bolts can fracture causing extensive damage. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 > Page 4014 22. Install differential in axle housing and verify gear mesh and contact pattern. 23. Install axle shafts. 24. Install wheel and tire assemblies. 25. Install differential cover and fill with gear lubricant. 26. Install propeller shaft with reference marks aligned. 27. Remove support and lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 Ring Gear: Service and Repair Rear Axle - 8 1/4 PINION GEAR/RING GEAR/ TONE RING REMOVAL NOTE: The ring gear and pinion are serviced in a matched set. Never replace one gear without replacing the other. 1. Remove differential from the axle housing. 2. Mark the companion flange and propeller shaft for installation alignment. 3. Disconnect propeller shaft from the companion flange and tie propeller shaft to underbody. 4. Place differential case in a suitable vise with soft metal jaw protectors. (Fig. 46). 5. Remove ring gear bolts from the differential case. 6. Drive ring gear off the differential case with a rawhide hammer (Fig. 46). 7. Install bolts into two of the threaded holes in the companion flange 1800 apart. 8. Position Holder 6719 against the companion Range and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so the Holder 6719 is held to the flange. 9. Hold companion flange with Holder 6719 and remove companion flange nut and washer. 10. Remove the companion flange with Remover C-452 (Fig. 47). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 > Page 4019 11. Remove pinion from housing (Fig. 48). 12. Remove pinion seal with a pry tool or slide-hammer mounted screw. 13. Remove oil slinger if equipped and front pinion bearing. 14. Remove front pinion bearing cup with Remover C-4345 and Handle C-4171 (Fig. 49). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 > Page 4020 15. Remove the rear bearing cup from housing (Fig. 50) with Remover C-4307 and Handle C-4171. 16. Remove collapsible preload spacer (Fig. 51). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 > Page 4021 17. Remove rear bearing from pinion (Fig. 52) with Puller/Press C-293-PA and Adapters C-293-47. 18. Remove depth shims from the pinion shaft and record shim thickness. INSTALLATION NOTE: The ring gear and pinion are serviced in a matched set. Do not replace the pinion without replacing the ring gear. If ring and pinion gears or bearings are replaced, Refer to Adjustments for Pinion Gear Depth Setting. 1. Apply Mopar(R) Door Ease or stick lubricant to outside surface of bearing cup. 2. Install rear pinion bearing cup (Fig. 53) with Installer C-4308 and Driver Handle C-4171 and verify cup is seated. 3. Apply Mopar(R) Door Ease or stick lubricant to outside surface of bearing cup. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 > Page 4022 4. Install front pinion bearing cup (Fig. 54) with Installer D-130 and Handle C-4171 and verify cup is seated. 5. Install front pinion bearing and oil slinger if equipped. 6. Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with Installer C-4076-B and Handle C-4735-1 (Fig. 55). 7. Place the proper thickness depth shim on the pinion shaft. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 > Page 4023 8. Install the rear bearing and slinger if equipped, on the pinion (Fig. 56) with Installer 6448 and a press. 9. Install a new collapsible preload spacer on pinion shaft and install the pinion into the housing (Fig. 57). 10. Install companion flange with Installer C-3718 and Holder 6719. 11. Install bolts into two of the threaded holes in the companion flange 180° apart. 12. Position Holder 6719 against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so the Holder 6719 is held to the flange. 13. Install the companion flange washer and a new nut on the pinion and tighten the pinion nut until there is zero bearing end-play. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 > Page 4024 14. Tighten the nut to 285 Nm (210 ft. lbs.) (Fig. 58). 15. 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 (Fig. 59). 16. Check bearing rotating torque with an inch pound torque wrench (Fig. 59). The torque necessary to rotate the pinion should be: - Original Bearings: 1 to 3 Nm (10 to 20 inch lbs.). - New Bearings: 2 to 5 Nm (15 to 35 inch lbs.). 17. Position exciter ring on differential case. 18. Using a brass drift, slowly and evenly tap the exciter ring into position. 19. Position ring gear on the differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment. 20. Invert the differential case in the vise. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 > Page 4025 21. Install new ring gear bolts and alternately tighten to 102 Nm (75 ft. lbs.) (Fig. 60). CAUTION: Do not reuse the bolts that held the ring gear to the differential case. The bolts can fracture causing extensive damage. 22. Install differential in housing and verify gear mesh and contact pattern. 23. Install differential cover and fill with gear lubricant. 24. Install propeller shaft with reference marks aligned. 25. Remove support and lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 > Page 4026 Ring Gear: Service and Repair Rear Axle - 9 1/4 PINION GEAR/RING GEAR/ TONE RING REMOVAL NOTE: The ring gear and pinion are serviced in a matched set. Never replace one gear without replacing the other. 1. Raise and support vehicle. 2. Remove wheel and tire assemblies. 3. Mark companion flange and propeller shaft for installation reference. 4. Disconnect propeller shaft from the companion flange and tie propeller shaft to underbody. 5. Remove axle shafts. 6. Remove differential from the differential housing. 7. Place differential case in a vise with soft metal jaw protectors. (Fig. 46). 8. Remove ring gear bolts from the differential case. 9. Drive ring gear off the differential case with a rawhide hammer (Fig. 46). 10. Install bolts into two of the threaded holes in the companion flange 180" apart. 11. Position Holder 6719 against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so the Holder 6719 is held to the flange. 12. Use Holder 6719 to hold companion flange and remove the companion flange nut and washer. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 > Page 4027 13. Remove the companion flange from the pinion with Remover C-452 (Fig. 47). 14. Remove the pinion from housing (Fig. 48). 15. Remove pinion seal with a pry tool or slide-hammer mounted screw. 16. Remove oil slinger if equipped and front pinion bearing. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 > Page 4028 17. Remove front pinion bearing cup with Remover C-4345 and Handle C-4171 (Fig. 49). 18. Remove the rear bearing cup from housing (Fig. 50) with Remover C-4307 and Handle C-4171. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 > Page 4029 19. Remove the collapsible preload spacer (Fig. 51). 20. Remove rear bearing from the pinion (Fig. 52) with Puller/Press C-293-PA and Adapters C-293-47. 21. Remove depth shims from the pinion shaft and record shim thickness. INSTALLATION NOTE: The ring gear and pinion are serviced in a matched set. Do not replace the pinion without replacing the ring gear. If ring and pinion gears or bearings are replaced, Refer to Adjustments for Pinion Gear Depth Setting. 1. Apply Mopar(R) Door Ease or stick lubricant to outside surface of bearing cup. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 > Page 4030 2. Install rear pinion bearing cup (Fig. 53) with Installer C-4308 and Driver Handle C-4171 and verify cup is seated. 3. Apply Mopar(R) Door Ease or stick lubricant to outside surface of bearing cup. 4. Install front pinion bearing cup (Fig. 54) with Installer D-130 and Handle C-4171 and verify cup is seated. 5. Install front pinion bearing. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 > Page 4031 6. Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with Installer C-4076-B and Handle C-4735-1 (Fig. 55). 7. Place the proper thickness depth shim on the pinion shaft. 8. Install the rear bearing on the pinion (Fig. 56) with Installer 6448 and a press. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 > Page 4032 9. Install a new collapsible preload spacer on pinion shaft and install the pinion into the housing (Fig. 57). 10. Install companion flange with Installer C-3718 and Holder 6719. 11. Install bolts into two of the threaded holes in the companion flange 180° apart. 12. Position Holder 6719 against the companion flange and install a bolt and washer into one of the remaining threaded holes. 'Tighten the bolts so the Holder 6719 is held to the flange. 13. Install the companion flange washer and a new nut on the pinion and tighten the pinion nut until there is zero bearing end-play. 14. Tighten the nut to 285 Nm (210 ft. lbs.) (Fig. 58). CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 > Page 4033 15. 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 (Fig. 59). 16. Check bearing rotating torque with an inch pound torque wrench (Fig. 59). The torque necessary to rotate the pinion should be: - Original Bearings: 1 to 3 Nm (10 to 20 inch lbs.). - New Bearings: 2 to 5 Nm (15 to 35 inch lbs.). 17. Position exciter ring on differential case. 18. Using a brass drift, slowly and evenly tap the exciter ring into position. 19. Position ring gear on the differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment. 20. Invert the differential case in the vise. 21. Install new ring gear bolts and alternately tighten to 156 Nm (115 ft. lbs.) (Fig. 60). CAUTION: Do not reuse the bolts that held the ring gear to the differential case. The bolts can fracture causing extensive damage. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Rear Axle - 8 1/4 > Page 4034 22. Install differential in axle housing and verify gear mesh and contact pattern. 23. Install axle shafts. 24. Install wheel and tire assemblies. 25. Install differential cover and fill with gear lubricant. 26. Install propeller shaft with reference marks aligned. 27. Remove support and lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Axle - 8 1/4 Seals and Gaskets: Service and Repair Rear Axle - 8 1/4 PINION SEAL REMOVAL 1. Raise and support the vehicle. 2. Mark the universal joint, companion flange and pinion shaft for installation reference. 3. Remove companion Range bolts and secure the shaft in an upright position to prevent damage to the rear universal joint. 4. Remove the wheel and tire assemblies. 5. Remove brake drums to prevent any drag. 6. Rotate companion flange three or four times and verify flange rotates smoothly. 7. Measure rotating torque of the pinion with a inch pound torque wrench and record the reading for installation reference. 8. Install bolts into two of the threaded holes in the companion flange 180° apart. 9. Position Holder 6719 against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so the Holder 6719 is held to the flange. 10. Remove the pinion nut and washer. 11. Remove companion flange with Remover C-452 (Fig. 21). 12. Remove pinion seal with a pry tool or slide hammer mounted screw. INSTALLATION NOTE: The outer perimeter of the seal is pre-coated with a special sealant. 1. Apply a light coating of gear lubricant on the lip of pinion seal. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Axle - 8 1/4 > Page 4039 2. Install new pinion seal with Installer C-4076-B and Handle C-4735-1 (Fig. 22) 3. Install companion flange on the end of the shaft with the reference marks aligned. 4. Install bolts into two of the threaded holes in the companion flange 1800 apart. 5. Position Holder 6719 against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so Holder 6719 is held to the flange. 6. Install companion flange on pinion shaft with Installer C-3718 and Holder 6719. 7. Install the pinion washer and a new pinion nut. The convex side of the washer must face outward. CAUTION: Do not exceed the minimum tightening torque when installing the companion flange retaining nut at this point. Damage to collapsible spacer or bearings may result. 8. Hold companion flange with Holder 6719 and tighten the pinion nut to 285 Nm (210 ft. lbs.) (Fig. 23). Rotate pinion several revolutions to ensure the bearing rollers are seated. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Axle - 8 1/4 > Page 4040 9. Rotate pinion with an inch pound torque wrench. Rotating torque should be equal to the reading recorded during removal plus an additional 0.56 Nm (5 inch lbs.) (Fig. 24). CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. If rotating torque is exceeded, a new collapsible spacer must be installed. 10. If rotating torque is low use Holder 6719 to hold the companion flange (Fig. 23) and tighten pinion nut in 6.8 Nm (5 ft. lbs.) increments until proper rotating torque is achieved. NOTE: The seal replacement is unacceptable if final pinion nut torque is less than 285 Nm (210 ft. lbs.). NOTE: The bearing rotating torque should be constant during a complete revolution of the pinion. If the rotating torque varies, this indicates a binding condition. 11. Install propeller shaft with the installation reference marks aligned. 12. Tighten companion flange bolts to 108 Nm (80 ft. lbs.). 13. Install the brake drums. 14. Check the differential housing lubricant level. 15. Install wheel and tire assemblies and lower the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Axle - 8 1/4 > Page 4041 Seals and Gaskets: Service and Repair Rear Axle - 9 1/4 PINION SEAL REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assemblies. 3. Mark the universal joint, companion flange, and pinion shaft for installation reference. 4. Remove propeller shaft from the companion flange. Secure the propeller shaft in an upright position to prevent damage to the rear universal joint. 5. Remove the brake drums to prevent any drag. 6. Rotate the companion flange three or four times. 7. Record pinion rotating torque with an inch pound torque wrench for installation reference. 8. Install socket head bolts into two of the threaded holes in the companion flange, 180° apart. 9. Position Holder 6719A against the companion flange and install a hex head bolt and washer into one of the remaining threaded holes. Tighten the bolt and washer so that the Holder 6719 is held to the flange. 10. Hold the flange with Holder 6719A and remove pinion nut and washer. 11. Remove companion flange with Remover C-452 (Fig. 21). 12. Remove pinion seal with pry tool or slide-hammer mounted screw. INSTALLATION NOTE: The outer perimeter of the seal is pre-coated with a special sealant. 1. Apply a light coating of gear lubricant on the lip of pinion seal. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Axle - 8 1/4 > Page 4042 2. Install new pinion seal with Installer C-3860-A and Handle C-4171 (Fig. 22) 3. Install companion flange on the end of the shaft with the reference marks aligned. 4. Install bolts into two of the threaded holes in the companion flange, 180° apart. 5. Position Holder 6719 against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so holder is held to the flange. 6. Install companion flange on pinion shaft with Installer C-3718 and Holder 6719. 7. Install pinion washer and a new pinion nut. The convex side of the washer must face outward. CAUTION: Do not exceed the minimum tightening torque when installing the companion flange retaining nut at this point. Damage to collapsible spacer or bearings may result. 8. Hold companion flange with Holder 6719 and tighten the pinion nut to 285 Nm (210 ft. lbs.) (Fig. 23). Rotate pinion several revolutions to ensure the bearing rollers are seated. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Axle - 8 1/4 > Page 4043 9. Rotate pinion using an inch pound torque wrench. Rotating torque should be equal to the reading recorded during removal plus an additional 0.56 Nm (5 inch lbs.) (Fig. 24). CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. If rotating torque is exceeded, a new collapsible spacer must be installed. 10. If rotating torque is low, use Holder 6719 to hold the companion flange (Fig. 23) and tighten pinion nut in 6.8 Nm (5 ft. lbs.) increments until proper rotating torque is achieved. NOTE: The bearing rotating torque should be constant during a complete revolution of the pinion. If the rotating torque varies, this indicates a binding condition. NOTE: The seal replacement is unacceptable if the final pinion nut torque is less than 285 Nm (210 ft. lbs.). 11. Install propeller shaft with the installation reference marks aligned. 12. Tighten the companion flange bolts to 108 Nm (80 ft. lbs.). 13. Install the brake drums. 14. Install wheel and tire assemblies and lower the vehicle. 15. Check the differential housing lubricant level. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle - 8 1/4 Axle Bearing: Service and Repair Rear Axle - 8 1/4 REMOVAL 1. Raise and support vehicle. 2. Remove axle shaft. 3. Remove axle shaft seal from the end of the axle tube with a small pry bar (Fig. 19). NOTE: The seal and bearing can be removed at the same time with the bearing removal tool. 4. Remove axle shaft bearing with Bearing Removal Tool Set 6310 and Adapter Foot 6310-9 (Fig. 20). INSTALLATION 1. Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube. 2. Install the axle shaft bearing with Installer C-4198 and Handle C-4171. Ensure bearing is installed straight and the tool is in contacts with the axle tube when seating the bearing. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle - 8 1/4 > Page 4049 NOTE: Install bearing with part number against the installer. 3. Install a new axle seal with Installer C-4076-B and Handle C-4735-1. When the tool contacts the axle tube, the seal is installed to the correct depth. 4. Coat the lip of the seal with axle lubricant for protection prior to installing the axle shaft. 5. Install the axle shaft. 6. Check and fill gear lubricant. 7. Remove support and lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle - 8 1/4 > Page 4050 Axle Bearing: Service and Repair Rear Axle - 9 1/4 REMOVAL 1. Remove axle shaft. 2. Remove axle shaft seal from the end of the axle tube with a small pry bar (Fig. 18). NOTE: The seal and bearing can be removed at the same time with the bearing removal tool. 3. Remove the axle shaft bearing from the axle tube with Bearing Removal Tool Set 6310, using Adapter Foot 6310-9 (Fig. 19). INSTALLATION 1. Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle - 8 1/4 > Page 4051 2. Install the axle shaft bearing with Installer C-4198 and Handle C-4171 (Fig. 20). Install the bearing with the bearing part number against the installer. Verify the bearing in installed straight and the tool fully contacts the axle tube when seating the bearing. 3. Install a new axle seal with Installer C-4076-B and Handle C-4735-1. When the tool contacts the axle tube, the seal is installed to the correct depth. 4. Coat the lip of the seal with axle lubricant for protection prior to installing the axle shaft. 5. Install the axle shaft. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana Axle Number Cross Reference Axle Shaft: Service and Repair Dana Axle Number Cross Reference New Model Number ............................................................................................................................. ..................................... Old Dana Model Number 174 ....................................................................................................................................................... .......................................................................... 28 181 ....................................................................... .......................................................................................................................................................... 30 186 .................................................................................................................................................. .................................................................... Super 30 194 .................................................................. .............................................................................................................................................................. . 35 198 ................................................................................................................................................ ...................................................................... Super 35 200 ................................................................ .............................................................................................................................................................. ... 36 216 .............................................................................................................................................. ................................................................................... 44 226 .............................................................. ........................................................................................................................................................ Super 44 229 ....................................................................................................................................... .......................................................................................... 50 248 ....................................................... .............................................................................................................................................................. ............ 60 267 ..................................................................................................................................... ............................................................................................ 70 286 ..................................................... .............................................................................................................................................................. .............. 80 First Letter of Suffix F .......................................................................................................................................................... ................................................................ Front R ................................................................................ ........................................................................................................................................... Rear Second Letter of Suffix B .......................................................................................................................................................... ................................................................ Beam I ................................................................................ ................................................................................................................................ Independent Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana Axle Number Cross Reference > Page 4057 Third Letter of Suffix I ............................................................................................................................................................ ................................................................. Iron A ................................................................................. ................................................................................................................................. Aluminum Examples: 248FBI ................................................................................................................................................. ................... Dana 60, Front, Beam Axle, Iron 186FIA .............................................................................................................................................. Dana Super 30, Front, Independent, Aluminum 226RBA ............................................................................................................................................... Dana Super 44, Rear, Beam Axle, Aluminum Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana Axle Number Cross Reference > Page 4058 Axle Shaft: Service and Repair Rear Axle - 8 1/4 AXLE SHAFTS REMOVAL 1. Place the transmission in NEUTRAL and raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove brake drum. 4. Clean all foreign material from housing cover area. 5. Remove the housing cover and drain lubricant. 6. Rotate differential case to access the pinion shaft lock screw. Remove lock screw and pinion shaft from differential case (Fig. 16). 7. Push axle shaft inward then remove axle shaft C-lock (Fig. 17). 8. Remove axle shaft being careful not to damage shaft bearing and seal. 9. Inspect axle shaft seal for leakage or damage. 10. Inspect axle shaft bearing contact surface for signs of brinelling, galling and pitting. INSTALLATION 1. Lubricate bearing bore and seal lip with gear lubricant. Insert axle shaft through seal, bearing and engage it into side gear splines. NOTE: Use care to prevent shaft splines from damaging axle shaft seal lip. 2. Insert C-lock in end of axle shaft. Push axle shaft outward to seat C-lock in side gear. 3. Insert pinion shaft into differential case and through thrust washers and differential pinions. 4. Align hole in shaft with hole in the differential case and install lock screw with Loctite on the threads. Tighten lock screw to 11 Nm (8 ft. lbs.). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana Axle Number Cross Reference > Page 4059 5. Install cover and fill with gear lubricant. 6. Install brake drum. 7. Install wheel and tire assemblies. 8. Remove support and lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana Axle Number Cross Reference > Page 4060 Axle Shaft: Service and Repair Rear Axle - 9 1/4 REMOVAL 1. Place transmission in neutral. 2. Raise and support the vehicle. 3. Remove wheel and tire assembly. 4. Remove brake drum. 5. Remove differential housing cover and drain lubricant. 6. Rotate differential case so pinion mate shaft lock screw is accessible. Remove lock screw and pinion mate shaft from differential case (Fig. 14). 7. Push axle shaft inward and remove axle shaft C-lock from the axle shaft (Fig. 15). 8. Remove axle shaft. Use care to prevent damage to axle shaft bearing and seal in the axle tube. INSTALLATION 1. Lubricate bearing bore and seal lip with gear lubricant. Insert axle shaft through seal, bearing, and engage it into side gear splines. NOTE: Use care to prevent shaft splines from damaging axle shaft seal. 2. Insert C-lock in end of axle shaft then push axle shaft outward to seat C-lock in side gear. 3. Insert pinion shaft into differential case and through thrust washers and differential pinions. 4. Align hole in shaft with hole in the differential case and install lock screw with Loctite on the threads. Tighten lock screw to 11 Nm (8 ft. lbs.). 5. Install differential cover and fill with gear lubricant. 6. Install brake drum. 7. Install wheel and tire. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana Axle Number Cross Reference > Page 4061 8. Remove support and lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > 8-1/4 Rear Axle Seals and Gaskets: Service and Repair 8-1/4 Rear Axle REMOVAL 1. Raise and support vehicle. 2. Remove axle shaft. 3. Remove axle shaft seal from the end of the axle tube with a small pry bar (Fig. 18). INSTALLATION 1. Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube. 2. Install a new axle seal with Installer C-4076-B and Handle C-4735-1. When the tool contacts the axle tube, the seal is installed to the correct depth. 3. Coat the lip of the seal with axle lubricant for protection prior to installing the axle shaft. 4. Install the axle shaft. 5. Check and fill gear lubricant. 6. Remove support and lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > 8-1/4 Rear Axle > Page 4066 Seals and Gaskets: Service and Repair 9-1/4 Rear Axle REMOVAL 1. Remove axle shaft. 2. Remove axle shaft seal from the end of the axle tube with a small pry bar (Fig. 16). INSTALLATION 1. Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube. 2. Install a new axle seal with Installer C-4076-B and Handle C-4735-1 (Fig. 17). When the tool contacts the axle tube, the seal is installed to the correct depth. 3. Coat the lip of the seal with axle lubricant for protection prior to installing the axle shaft. 4. Install the axle shaft. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Mechanical Specifications Wheel Bearing: Mechanical Specifications Hub/Bearing Spindle Nut 185 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Mechanical Specifications > Page 4071 Wheel Bearing: Fluid Type Specifications Use Mopar Multi-Purpose Lubricant or equivalent. (labeled NGLI Grade 2 EP, GC-LB) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 4072 Wheel Bearing: Service and Repair REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove brake caliper, rotor, and ABS wheel speed sensor if equipped. 4. Remove hub/bearing spindle nut and discard nut. CAUTION: The hub/bearing spindle nut can not be re-used. INSTALLATION 1. Slide hub/bearing on spindle. 2. Install new spindle nut and tighten to 251 Nm (185 ft. lbs.). 3. Install brake rotor, caliper, and ABS wheel speed sensor if equipped. 4. Install wheel and tire assembly. 5. Remove support and lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Specifications Wheel Hub: Specifications Hub/Bearing Spindle Nut 185 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Specifications > Page 4076 Wheel Hub: Service and Repair REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove brake caliper, rotor, and ABS wheel speed sensor if equipped. 4. Remove hub/bearing spindle nut and discard nut. CAUTION: The hub/bearing spindle nut can not be re-used. INSTALLATION 1. Slide hub/bearing on spindle. 2. Install new spindle nut and tighten to 251 Nm (185 ft. lbs.). 3. Install brake rotor, caliper, and ABS wheel speed sensor if equipped. 4. Install wheel and tire assembly. 5. Remove support and lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Specifications Center Support: Specifications Center Bearing Bolts ........................................................................................................................... .................................................... 68 Nm (50 ft. lbs.) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Companion Flange > Component Information > Specifications Companion Flange: Specifications Transfer Case Flange Bolts 22.5 ft.lb Companion Flange Bolts 80 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Description and Operation Drive/Propeller Shaft: Description and Operation DESCRIPTION A propeller shaft (Fig. 1) is the shaft which connects the transfer case to the front axle. This is the link through which the engine power is transmitted to the axle. The propeller shaft is designed and built with the yoke lugs in line with each other which is called zero phasing. This design produces the smoothest running condition, an out-of-phase shaft can cause a vibration. Tubular propeller shafts are balanced by the manufacturer with weights spot welded to the tube. Use the exact replacement parts when installing the propeller shafts. The use of the correct replacement parts helps to ensure safe operation. All fasteners must be torqued to the specified values for safe operation. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Description and Operation > Page 4087 Also make alignment reference marks (Fig. 3) on the propeller shaft yoke and axle, or transmission, yoke prior to servicing. This helps to eliminate possible vibration. CAUTION: Do not allow the propeller shaft to drop or hang from any propeller shaft joint during removal. Attach the propeller shaft to the vehicle underside with wire to prevent damage to the joints. OPERATION The propeller shaft must operate through constantly changing relative angles between the transmission and axle. It must also be capable of changing length while transmitting torque. The axle rides suspended by springs in a floating motion. The propeller shaft must be able to change operating angles when going over various road surfaces. This is accomplished through universal joints/constant velocity joint, which permit the propeller shaft to operate at different angles. The slip joints (or yokes) permit contraction or expansion. Before undercoating a vehicle, the propeller shaft and the U-joints should be covered to prevent an out-of-balance condition and driveline vibration. CAUTION: Use original equipment replacement parts for attaching the propeller shafts. The specified torque must always be applied when tightening the fasteners. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Description and Operation > Page 4088 Drive/Propeller Shaft: Testing and Inspection VIBRATION Tires that are out-of-round, or wheels that are unbalanced, will cause a low frequency vibration. Brake drums that are unbalanced will cause a harsh, low frequency vibration. Driveline vibration can also result from loose or damaged engine mounts. Propeller shaft vibration increases as the vehicle speed is increased. A vibration that occurs within a specific speed range is not usually caused by a propeller shaft being unbalanced. Defective universal joints, or an incorrect propeller shaft angle, are usually the cause of such a vibration. DRIVELINE VIBRATION BALANCE NOTE: Removing and re-indexing the propeller shaft 1800 relative to the yoke may eliminate some vibrations. If propeller shaft is suspected of being unbalanced, it can be verified with the following procedure: 1. Raise the vehicle. 2. Clean all the foreign material from the propeller shaft and the universal joints. 3. Inspect the propeller shaft for missing balance weights, broken welds, and bent areas. If the propeller shaft is bent, it must be replaced. 4. Inspect the universal joints to ensure that they are not worn, are properly installed, and are correctly aligned with the shaft. 5. Check the universal joint clamp screws torque. 6. Remove the wheels and tires. Install the wheel lug nuts to retain the brake drums or rotors. 7. Mark and number the shaft six inches from the yoke end at four positions 90° apart. 8. Run and accelerate the vehicle until vibration occurs. Note the intensity and speed the vibration occurred. Stop the engine. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Description and Operation > Page 4089 9. Install a screw clamp at position 1 (Fig. 4). 10. Start the engine and re-check for vibration. If there is little or no change in vibration, move the clamp to one of the other three positions. Repeat the vibration test. 11. If there is no difference in vibration at the other positions, the source of the vibration may not be propeller shaft. 12. If the vibration decreased, install a second clamp (Fig. 5) and repeat the test. 13. If the additional clamp causes an additional vibration, separate the clamps (1/2 inch above and below the mark). Repeat the vibration test (Fig. 6). 14. Increase distance between the clamp screws and repeat the test until the amount of vibration is at the lowest level. Bend the slack end of the clamps so the screws will not loosen. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Description and Operation > Page 4090 15. If the vibration remains unacceptable, apply the same steps to the front end of the propeller shaft. 16. Install the wheel and tires. Lower the vehicle. RUNOUT 1. Remove dirt, rust, paint and undercoating from the propeller shaft surface where the dial indicator will contact the shaft. 2. The dial indicator must be installed perpendicular to the shaft surface. 3. Measure runout at the center and ends of the shaft sufficiently far away from weld areas to ensure that the effects of the weld process will not enter into the measurements. 4. Refer to Runout Specifications chart. 5. If the propeller shaft runout is out of specification, remove the propeller shaft, index the shaft 180°, and re-install the propeller shaft. Measure shaft runout again. 6. If the propeller shaft runout is now within specifications, mark the shaft and yokes for proper orientation. 7. If the propeller shaft runout is not within specifications, verify that the runout of the transmission/ transfer case and axle are within specifications. Correct as necessary and re-measure propeller shaft runout. 8. Replace the propeller shaft if the runout still exceeds the limits. RUNOUT SPECIFICATIONS Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft-Front Drive/Propeller Shaft: Service and Repair Propeller Shaft-Front PROPELLER SHAFT - FRONT REMOVAL 1. Position transmission and transfer case to their neutral positions. Raise and support vehicle. Remove skid plate, if equipped. 2. Mark a line across the transfer case flange and C/V for installation reference. 3. Mark a line across the propeller shaft flange yoke and front axle companion flange for installation reference. 4. Remove companion flange bolts (Fig. 11). 5. Remove transfer case flange bolts and remove propeller shaft. INSTALLATION 1. Install propeller shaft with all reference marks aligned. 2. Loosely install bolts to C/V and transfer case companion flange. 3. Install bolts to companion flange and Range yoke and tighten to 108 Nm (80 ft. lbs.). 4. Tighten bolts to transfer case companion flange to 30.5 Nm (22.5 ft. lbs.). 5. Install skid plate, if equipped. 6. Lower vehicle and road test to verify repair. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft-Front > Page 4093 Drive/Propeller Shaft: Service and Repair Propeller Shaft - Rear PROPELLER SHAFT REAR REMOVAL 1. Place the transmission into the Neutral position. 2. Raise and support vehicle on safety stands. 3. Mark a line across the axle companion flange and flange yoke for installation reference. 4. Mark an outline of the center bearing on the support bracket for installation reference, if equipped. 5. Mark an outline of the heat shield on the center bearing for installation reference, if equipped. 6. Remove center bearing and heat shield bolts, if equipped. 7. Remove companion flange bolts. 8. Slide slip yoke off of the transmission, or transfer case, output shaft and remove the propeller shaft (Fig. 12). INSTALLATION 1. Slide the slip yoke onto the transmission, or transfer case, output shaft. 2. Align and install the center bearing and heat shield to the support bracket, if necessary. Install the bolts and tighten to 68 Nm (50 ft. lbs.). 3. Align companion flange reference mark with flange yoke mark. 4. Install companion flange bolts and tighten to 108 Nm (80 ft. lbs.). 5. Lower the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft-Front > Page 4094 Drive/Propeller Shaft: Service and Repair Standard Procedures STANDARD PROCEDURES - PROPELLER SHAFT ANGLE The procedure applies to both the front propeller shafts and the rear propeller shaft if equipped. 1. Raise and support the vehicle at the axles as level as possible. Allow the wheels and propeller shaft to turn. 2. Remove any external bearing snap rings from universal joint if equipped, so the inclinometer base will sits flat. 3. Rotate the shaft until transmission/transfer case output yoke bearing cap is facing downward, if necessary Always make measurements from front to rear. 4. Place Inclinometer on yoke bearing cap, or the pinion flange ring, (A) parallel to the shaft (Fig. 7). Center bubble in sight glass and record measurement. This measurement will give you the transmission or Output Yoke Angle (A). 5. Rotate propeller shaft 90 degrees and place Inclinometer on yoke bearing cap parallel to the shaft (Fig. 8). Center bubble in sight glass and record measurement. This measurement can also be taken at the rear end of the shaft. This measurement will give you the propeller shaft angle (C). 6. Subtract smaller figure from larger (C minus A) to obtain transmission output operating angle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft-Front > Page 4095 7. Rotate propeller shaft 90 degrees and place Inclinometer on pinion yoke bearing cap parallel to the shaft (Fig. 9). Center bubble in sight glass and record measurement. This measurement will give you the pinion shaft or input yoke angle (B). 8. Subtract smaller figure from larger (C minus B) to obtain axle Input Operating Angle. Refer to rules given below and the example in (Fig. 10) for additional information. Good cancellation of U-joint operating angles (within 1°). - Operating angles less than 3°. - At least 1/2 of one degree continuous operating (propeller shaft) angle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair Universal Joint: Service and Repair SINGLE CARDAN UNIVERSAL JOINTS DISASSEMBLY NOTE: The following procedure is described for a propeller shaft equipped with only a cardan joint in the tube yoke. If the propeller shaft is equipped with a companion yoke, simply repeat the following steps to remove the cardan joint from the companion yoke after removing the cardan joint from the tube yoke. Individual components of cardan universal joints are not serviceable. If worn or leaking, they must be replaced as an assembly. 1. Remove the propeller shaft. 2. Using a soft drift, tap the outside of the bearing cap assembly to loosen snap ring. 3. Remove snap rings from both sides of yoke (Fig. 13). 4. Set the yoke in an arbor press or vise with a socket whose inside diameter is large enough to receive the bearing cap positioned beneath the yoke. 5. Position the yoke with the grease fitting, if equipped, pointing up. 6. Place a socket with an outside diameter smaller than the upper bearing cap on the upper bearing cap and press the cap through the yoke to release the lower bearing cap (Fig. 14). 7. If the bearing cap will not pull out of the yoke by hand after pressing, tap the yoke ear near the bearing cap to dislodge the cap. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Page 4099 8. To remove the opposite bearing cap, turn the yoke over and straighten the cross in the open hole. Then, carefully press the end of the cross until the remaining bearing cap can be removed (Fig. 15). CAUTION: If the cross or bearing cap are not straight during installation, the bearing cap will score the walls of the yoke bore and damage can occur. ASSEMBLY NOTE: The following procedure is described for a propeller shaft equipped with only a cardan joint in the tube yoke. If the propeller shaft is equipped with a companion yoke, simply repeat the following steps to remove the cardan joint from the companion yoke after removing the cardan joint from the tube yoke. 1. Apply extreme pressure (EP) N.L.G.I. Grade 1 or 2 grease to inside of yoke bores to aid in installation. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Page 4100 2. Position the cross in the yoke with its lube fitting, if equipped, pointing up (Fig. 16). 3. Place a bearing cap over the trunnion and align the cap with the yoke bore (Fig. 17). Keep the needle bearings upright in the bearing assembly. A needle bearing lying at the bottom of the cap will prevent proper assembly. 4. Press the bearing cap into the yoke bore enough to install a snap ring. 5. Install a snap ring. 6. Repeat Step 3 and Step 4 to install the opposite bearing cap. If the joint is stiff or binding, strike the yoke with a soft hammer to seat the needle bearings. 7. Add grease to lube fitting, if equipped. 8. Install the propeller shaft. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications Torque Specifications Torque Specifications Engine Component Torque 4.7 L Flexplate bolts 60 Nm (45 ft. lbs.) Follow the tightening sequence in the image provided. 5.9 L " 75 Nm (55 ft. lbs.) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 4104 Flex Plate: Service and Repair REMOVAL 1. Remove the transmission. 2. Remove the bolts and flexplate. INSTALLATION 1. Position the flexplate onto the crankshaft and install the bolts hand tight. 2. Tighten the flexplate retaining bolts to 60 Nm (45 ft. lbs.) in the sequence shown (Fig. 71). 3. Install the transmission. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Locations Overdrive Indicator Lamp: Locations The Overdrive OFF Indicator (VFD) is part of the cluster electronic circuit board, and is visible through a cutout located in the lower right corner of the cluster overlay. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Locations > Page 4110 Overdrive Indicator Lamp: Description and Operation OVERDRIVE OFF INDICATOR An overdrive OFF indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional overdrive automatic transmission, this indicator is electronically disabled. The overdrive OFF indicator consists of the text "O/D OFF", which appears in the lower portion of the electronic gear selector indicator Vacuum Fluorescent Display (VFD). The VFD is part of the cluster electronic circuit board, and is visible through a cutout located in the lower right corner of the cluster overlay. The dark lens of the VFD prevents the indicator from being clearly visible when it is not illuminated. The text "O/D OFF" appears in an amber color and at the same lighting level as the gear selector indicator information when it is illuminated by the instrument cluster electronic circuit board. The overdrive OFF indicator is serviced as a unit with the VFD in the instrument cluster. The overdrive OFF indicator gives an indication to the vehicle operator when the OFF position of the overdrive OFF switch has been selected, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The overdrive OFF indicator receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions; therefore, the indicator will always be OFF when the ignition switch is in any position except ON or Start. The indicator only illuminates when it is switched to ground by the instrument cluster circuitry. The instrument cluster will turn ON the overdrive OFF indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the overdrive OFF indicator is illuminated for about two seconds as a bulb test. - Overdrive OFF Lamp-ON Message - Each time the cluster receives an overdrive OFF lamp-ON message from the PCM indicating that the OFF position of the overdrive OFF switch has been selected, the overdrive OFF indicator will be illuminated. The indicator remains illuminated until the cluster receives an overdrive OFF lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the overdrive OFF indicator will be turned ON, then OFF again during the VFD portion of the test to confirm the functionality of the VFD, and again during the bulb check portion of the test to confirm the functionality of the cluster control circuitry. The PCM continually monitors the overdrive OFF switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper overdrive OFF lamp-ON and lamp-OFF messages to the instrument cluster. For further diagnosis of the overdrive OFF indicator or the instrument cluster circuitry that controls the indicator, (Refer to INSTRUMENT/CLUSTER DIAGNOSIS AND TESTING). For proper diagnosis of the overdrive control system, the PCM, the PCI data bus, or the message inputs to the instrument cluster that control the overdrive OFF indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair Shift Indicator: Service and Repair GEARSHIFT INDICATOR REMOVAL The following service procedures apply only to the mechanical gear selector indicator. The electronic gear selector indicator is integral to the instrument cluster and can only be serviced by replacement of the instrument cluster unit. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument cluster from the instrument panel. Fig. 13 3. Remove the two screws that secure the gear selector indicator mechanism to the back of the instrument cluster housing (Fig. 13). 4. Remove the gear selector indicator mechanism from the back of the instrument cluster housing. 5. Remove the steering column opening cover from the instrument panel. Fig. 14 6. Disengage the loop end of the gear selector indicator cable from the lever on the left side of the steering column (Fig. 14). 7. Squeeze the sides of the plastic adjuster and bracket unit to disengage the tabs that secure it to the sides of the steering column window. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair > Page 4114 8. Remove the gear selector indicator mechanism and cable unit from the instrument panel. INSTALLATION The following service procedures apply only to the mechanical gear selector indicator. The electronic gear selector indicator is integral to the instrument cluster and can only be serviced by replacement of the instrument cluster unit. 1. Position the gear selector indicator mechanism and cable unit to the instrument panel. 2. Squeeze the sides of the plastic adjuster and bracket unit and engage the tabs that secure it with the sides of the steering column window. 3. Engage the loop end of the gear selector indicator cable onto the lever on the left side of the steering column (Fig. 14). 4. Position the gear selector indicator mechanism onto the back of the instrument cluster housing. 5. Install and tighten the two screws that secure the gear selector indicator mechanism to the back of the instrument cluster housing. Tighten the screws to 2.2 N.m (20 in. lbs.). 6. Install the instrument cluster onto the instrument panel. 7. Check the gear selector indicator for proper calibration. If adjustment is needed, 8. Install the steering column opening cover onto the instrument panel. 9. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Locations Temperature Warning Indicator - A/T: Locations The transmission over-temperature indicator is located in the Information Center area of the instrument cluster, to the left of center. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Locations > Page 4118 Temperature Warning Indicator - A/T: Description and Operation A transmission over-temperature indicator lamp is standard equipment on all instrument clusters. The transmission over-temperature indicator is located in the Information Center area of the instrument cluster, to the left of center. The transmission over-temperature indicator consists of a stencilled cutout of the words "TRANS TEMP" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red lens behind the cutout in the opaque layer of the overlay causes the "TRANS TEMP" text to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by a Light Emitting Diode (LED) soldered onto the instrument cluster electronic circuit board. The transmission overtemperature indicator is serviced as a unit with the instrument cluster. The transmission over-temperature indicator gives an indication to the vehicle operator when the trans- mission fluid temperature is excessive, which may lead to accelerated transmission component wear or failure. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The transmission over-temperature indicator Light Emitting Diode (LED) receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions; therefore, the LED will always be OFF when the ignition switch is in any position except ON or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the transmission over-temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the transmission over-temperature indicator is illuminated for about two seconds as a bulb test. - Trans Over-Temp Lamp-ON Message - Each time the cluster receives a trans over-temp lamp-ON message from the PCM indicating that the transmission fluid temperature is 135 °C (275 °F) or higher, the indicator will be illuminated and a single chime tone is sounded. The lamp remains illuminated until the cluster receives a trans over-temp lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the transmission over-temperature indicator is cycled OFF and then on again by the appropriate trans over-temp messages from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition, then sends the proper messages to the instrument cluster. If the instrument cluster turns ON the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission and/or the transmission cooling system are being overloaded or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the transmission temperature sensor, the PCM, the PCI data bus, or the message inputs to the instrument cluster that control the transmission over-temperature indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle Technical Service Bulletin # 08-032-00A Date: 001229 4X4 Service Lamp - ON, 4X2 Vehicle NUMBER: 08-032-00 REV. A GROUP: Electrical DATE: Dec. 29, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-032-00, DATED OCTOBER 20, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS BULLETIN IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS SUBJECT: "Service 4WD" Lamp Illuminated On 4X2 Vehicles OVERVIEW: This bulletin involves installing a revised HVAC control assembly. MODELS: NOTE: THIS BULLETIN APPLIES TO 4X2 VEHICLES BUILT BEFORE OCTOBER 13, 2000 (MDH 1013XX). SYMPTOM/CONDITION: The "Service 4WD" lamp is illuminated even though the truck is not a 4X4 vehicle. DIAGNOSIS: Start the engine. Once the instrument cluster bulb check has been completed, verify that the "Service 4WD" lamp is illuminated. If the "Service 4WD" lamp is illuminated, perform the Repair Procedure. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 4128 FAILURE CODE: Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING INSTRUMENT PANEL COMPONENT SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is equipped with an automatic transmission, turn the ignition switch to the Unlock position, set the park brake, and place the transmission gear selector lever in the LOW position. 3. If the vehicle is equipped with a tilt column, set the tilt steering column in its lowest position. 4. Reach under the left end of the instrument panel to access and unsnap the rod end clip on the park brake release link and disengage the link from the back of the handle (Fig. 1). 5. Remove the three screws that secure the lower edge of the steering column opening cover to the lower instrument panel reinforcement. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 4129 6. Using a trim stick or another suitable wide flat-bladed tool, gently pry the upper edge of the steering column opening cover just below the cluster bezel on each side of the steering column away from the instrument panel far enough to disengage each of the snap clip retainers from their receptacles in the instrument panel base trim (Fig. 2). 7. Remove the steering column opening cover from the instrument panel. 8. Remove the two screws in the hooded area above the instrument cluster that secures the cluster bezel to the instrument panel base trim (Fig. 3). 9. Using a trim stick or another suitable wide flat-bladed tool, gently pry around the perimeter of the cluster bezel to disengage the snap clips from their receptacles in the instrument panel base trim. 10. Pull the right side of the cluster bezel away from the instrument panel far enough to access and disconnect the instrument panel wire harness connector for the headlamp switch from the switch connector receptacle. 11. Pull the left side of the cluster bezel away from the instrument panel far enough to access and disconnect the instrument panel wire harness connectors from the receptacles for the passenger airbag ON/OFF switch (if equipped), the rear window defogger switch (if equipped), the HVAC control, and the transfer case switch (if equipped). 12. Remove the cluster bezel from the instrument panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 4130 13. Remove the four screws that secure the HVAC control to the cluster bezel (Fig. 4). 14. Remove the HVAC control from the instrument panel. 15. Position the new HVAC control (see Parts Required section) in the cluster bezel and secure it with four screws. Tighten the screws to 2.2 Nm (17 i3 in. lbs.) 16. Position the cluster bezel to the instrument panel. 17. Pull the left side of the cluster bezel away from the instrument panel far enough to access and reconnect the instrument panel wire harness connectors to the receptacles for the passenger airbag on/off switch (if equipped), the rear window defogger switch (if equipped), the HVAC control, and the transfer case switch (if equipped). 18. Pull the right side of the cluster bezel away from the instrument panel far enough to access and reconnect the instrument panel wire harness connector for the headlamp switch to the switch connector receptacle. 19. Align the snap clips on the cluster bezel with the receptacles in the instrument panel base trim. 20. Using hand pressure, press firmly on the cluster bezel over each of the snap clip locations until each snap clip is fully engaged in their receptacle. 21. Install and tighten the two screws in the hooded area above the instrument cluster that secure the cluster bezel to the instrument panel base trim (Fig. 3). Tighten the screws to 2.2 Nm (20 in. lbs.). 22. Position the steering column opening cover to the instrument panel. 23. Align the snap clip retainers on the steering column opening cover with the receptacles in the instrument panel base trim. 24. Using hand pressure, press firmly on the steering column opening cover over the snap clip locations until each of the snap clips are fully engaged in their receptacle. 25. Install and tighten the three screws that secure the lower edge of the steering column opening cover to the instrument structural support. Tighten the screws to 2.2 Nm (20 in.lbs.). 26. Reach under the left end of the instrument panel to access and engage the park brake release link to the back of the handle. Then snap the rod end clip over the park brake release link to secure the connection. 27. Reconnect the battery negative cable. 28. On vehicles equipped with A/C, perform the A/C cool down test using the DRBIII(R). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle Technical Service Bulletin # 08-032-00A Date: 001229 4X4 Service Lamp - ON, 4X2 Vehicle NUMBER: 08-032-00 REV. A GROUP: Electrical DATE: Dec. 29, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-032-00, DATED OCTOBER 20, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS BULLETIN IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS SUBJECT: "Service 4WD" Lamp Illuminated On 4X2 Vehicles OVERVIEW: This bulletin involves installing a revised HVAC control assembly. MODELS: NOTE: THIS BULLETIN APPLIES TO 4X2 VEHICLES BUILT BEFORE OCTOBER 13, 2000 (MDH 1013XX). SYMPTOM/CONDITION: The "Service 4WD" lamp is illuminated even though the truck is not a 4X4 vehicle. DIAGNOSIS: Start the engine. Once the instrument cluster bulb check has been completed, verify that the "Service 4WD" lamp is illuminated. If the "Service 4WD" lamp is illuminated, perform the Repair Procedure. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 4136 FAILURE CODE: Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING INSTRUMENT PANEL COMPONENT SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is equipped with an automatic transmission, turn the ignition switch to the Unlock position, set the park brake, and place the transmission gear selector lever in the LOW position. 3. If the vehicle is equipped with a tilt column, set the tilt steering column in its lowest position. 4. Reach under the left end of the instrument panel to access and unsnap the rod end clip on the park brake release link and disengage the link from the back of the handle (Fig. 1). 5. Remove the three screws that secure the lower edge of the steering column opening cover to the lower instrument panel reinforcement. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 4137 6. Using a trim stick or another suitable wide flat-bladed tool, gently pry the upper edge of the steering column opening cover just below the cluster bezel on each side of the steering column away from the instrument panel far enough to disengage each of the snap clip retainers from their receptacles in the instrument panel base trim (Fig. 2). 7. Remove the steering column opening cover from the instrument panel. 8. Remove the two screws in the hooded area above the instrument cluster that secures the cluster bezel to the instrument panel base trim (Fig. 3). 9. Using a trim stick or another suitable wide flat-bladed tool, gently pry around the perimeter of the cluster bezel to disengage the snap clips from their receptacles in the instrument panel base trim. 10. Pull the right side of the cluster bezel away from the instrument panel far enough to access and disconnect the instrument panel wire harness connector for the headlamp switch from the switch connector receptacle. 11. Pull the left side of the cluster bezel away from the instrument panel far enough to access and disconnect the instrument panel wire harness connectors from the receptacles for the passenger airbag ON/OFF switch (if equipped), the rear window defogger switch (if equipped), the HVAC control, and the transfer case switch (if equipped). 12. Remove the cluster bezel from the instrument panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 4138 13. Remove the four screws that secure the HVAC control to the cluster bezel (Fig. 4). 14. Remove the HVAC control from the instrument panel. 15. Position the new HVAC control (see Parts Required section) in the cluster bezel and secure it with four screws. Tighten the screws to 2.2 Nm (17 i3 in. lbs.) 16. Position the cluster bezel to the instrument panel. 17. Pull the left side of the cluster bezel away from the instrument panel far enough to access and reconnect the instrument panel wire harness connectors to the receptacles for the passenger airbag on/off switch (if equipped), the rear window defogger switch (if equipped), the HVAC control, and the transfer case switch (if equipped). 18. Pull the right side of the cluster bezel away from the instrument panel far enough to access and reconnect the instrument panel wire harness connector for the headlamp switch to the switch connector receptacle. 19. Align the snap clips on the cluster bezel with the receptacles in the instrument panel base trim. 20. Using hand pressure, press firmly on the cluster bezel over each of the snap clip locations until each snap clip is fully engaged in their receptacle. 21. Install and tighten the two screws in the hooded area above the instrument cluster that secure the cluster bezel to the instrument panel base trim (Fig. 3). Tighten the screws to 2.2 Nm (20 in. lbs.). 22. Position the steering column opening cover to the instrument panel. 23. Align the snap clip retainers on the steering column opening cover with the receptacles in the instrument panel base trim. 24. Using hand pressure, press firmly on the steering column opening cover over the snap clip locations until each of the snap clips are fully engaged in their receptacle. 25. Install and tighten the three screws that secure the lower edge of the steering column opening cover to the instrument structural support. Tighten the screws to 2.2 Nm (20 in.lbs.). 26. Reach under the left end of the instrument panel to access and engage the park brake release link to the back of the handle. Then snap the rod end clip over the park brake release link to secure the connection. 27. Reconnect the battery negative cable. 28. On vehicles equipped with A/C, perform the A/C cool down test using the DRBIII(R). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Service Precautions Fluid - M/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Overdrive Switch, M/T > Component Information > Diagrams Overdrive Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Overdrive Switch, M/T > Component Information > Diagrams Overdrive Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > Customer Interest for Transmission Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts Transmission Control Module: Customer Interest A/T - 45RFE/545RFE Harsh Upshifts/Downshifts NUMBER: 18-025-01 GROUP: Vehicle Performance DATE: October 15, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-09-00, DATED SEPTEMBER 15, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. **ASTERISKS** HAVE BEEN USED TO HIGHLIGHT CHANGES. THIS BULLETIN ADDS A MODEL YEAR AND REQUIRES A REPROGRAMMING OF THE 1999 AND 2000 GRAND CHEROKEE POWERTRAIN CONTROL MODULE (PCM). SUBJECT: 45RFE **and 545RFE Shift** Quality Enhancements for the** 2-3, 4-5, and 5-4** Shifts OVERVIEW: This bulletin involves selectively erasing and reprogramming the **Transmission Control Module (TCM) with new software: '99-'01 WJ (PN 05019701AC Ver 9.3), '00 AN/DN (PN 05018454AB Ver 9.1), or '01 AN/DN (PN 56028285A1 Ver 8.4), and requires reprogramming of the Powertrain Control Module (PCM) for the 1999 and 2000 Grand Cherokees only (with calibration 99Cal20 (1999) or 00Cal17 (2000).** NOTE: THE 2001 GRAND CHEROKEE DOES NOT REQUIRE REPROGRAMMING OF THE PCM AS IT IS ALREADY AT THE CORRECT CALIBRATION LEVEL. NOTE: WHENEVER A PCM OR TCM IS REPLACED OR REPROGRAMMED, THE SOFTWARE OF THE PCM MUST BE VERIFIED AS HAVING THE LATEST REVISION LEVEL. MODELS: 2000 (AN) Dakota **2001** 2000 (DN) Durango **2001** 1999 (WJ) Grand Cherokee **2001 ** NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 4.7L ENGINE AND A 45RFE **OR 545RFE** TRANSMISSION. SYMPTOM/CONDITION: Some vehicles **may exhibit one or more of the following performance conditions **: 1. A harsh 2-3 upshift causing a powertrain clunk or shudder when accelerating. 2. **A harsh 4-5 upshift ('01 Grand Cherokee only).** 3. **A harsh 5-4 downshift ('01 Grand Cherokee only).** NOTE: THIS REVISION TO THE TCM SOFTWARE ADDRESSES THE ABOVE SHIFT QUALITY CONDITIONS FOR ALL VEHICLES AND, ADDS A FINAL GEAR RATIO TO THE **1999 AND 2000 MY** GRAND CHEROKEE TRANSMISSION ONLY. (2001 MY GRAND CHEROKEE ALREADY HAS THIS UPGRADE.) NOTE: TO MAINTAIN EMISSIONS COMPLIANCE, GRAND CHEROKEE VEHICLES THAT ARE EQUIPPED WITH A FEDERAL EMISSION SYSTEM (SALES CODE NAA) MUST HAVE THEIR PCM REPROGRAMMED. IF THE SOFTWARE LEVEL IS AT OR HIGHER THAN THOSE IN THE OVERVIEW ABOVE, OR IF THE GRAND CHEROKEE HAS A CALIFORNIA EMISSIONS SYSTEM (SALES CODE NAE), REPROGRAMMING IS NOT NECESSARY. DIAGNOSIS PROCEDURES: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRBIII(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 performing this repair. If no DTC's are present, and the above symptom has been experienced, perform the Repair Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > Customer Interest for Transmission Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts > Page 4160 Procedure. NOTE: **IF OTHER PERFORMANCE ISSUES REMAIN AFTER THE REPAIR PROCEDURE HAS BEEN PERFORMED THEY DO NOT RELATE TO THIS BULLETIN. REFER TO THE PROPER SERVICE OR DIAGNOSTIC PROCEDURES MANUAL(S) FOR FURTHER ASSISTANCE.** PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD **2093 OR HIGHER AND DRB III(R) VERSION 52.3 WILL BE IN THE DEALERSHIPS ON OCTOBER 15, 2001.)** REPAIR PROCEDURE: 1. Log onto the MDS2 (Mopar Diagnostic System). 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III(R), MDS2, AND VEHICLE ESTABLISH COMMUNICATION. 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. 3. Push the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) 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. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. 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, 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 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > Customer Interest for Transmission Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts > Page 4161 7. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 8. 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts Transmission Control Module: All Technical Service Bulletins A/T - 45RFE/545RFE Harsh Upshifts/Downshifts NUMBER: 18-025-01 GROUP: Vehicle Performance DATE: October 15, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-09-00, DATED SEPTEMBER 15, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. **ASTERISKS** HAVE BEEN USED TO HIGHLIGHT CHANGES. THIS BULLETIN ADDS A MODEL YEAR AND REQUIRES A REPROGRAMMING OF THE 1999 AND 2000 GRAND CHEROKEE POWERTRAIN CONTROL MODULE (PCM). SUBJECT: 45RFE **and 545RFE Shift** Quality Enhancements for the** 2-3, 4-5, and 5-4** Shifts OVERVIEW: This bulletin involves selectively erasing and reprogramming the **Transmission Control Module (TCM) with new software: '99-'01 WJ (PN 05019701AC Ver 9.3), '00 AN/DN (PN 05018454AB Ver 9.1), or '01 AN/DN (PN 56028285A1 Ver 8.4), and requires reprogramming of the Powertrain Control Module (PCM) for the 1999 and 2000 Grand Cherokees only (with calibration 99Cal20 (1999) or 00Cal17 (2000).** NOTE: THE 2001 GRAND CHEROKEE DOES NOT REQUIRE REPROGRAMMING OF THE PCM AS IT IS ALREADY AT THE CORRECT CALIBRATION LEVEL. NOTE: WHENEVER A PCM OR TCM IS REPLACED OR REPROGRAMMED, THE SOFTWARE OF THE PCM MUST BE VERIFIED AS HAVING THE LATEST REVISION LEVEL. MODELS: 2000 (AN) Dakota **2001** 2000 (DN) Durango **2001** 1999 (WJ) Grand Cherokee **2001 ** NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 4.7L ENGINE AND A 45RFE **OR 545RFE** TRANSMISSION. SYMPTOM/CONDITION: Some vehicles **may exhibit one or more of the following performance conditions **: 1. A harsh 2-3 upshift causing a powertrain clunk or shudder when accelerating. 2. **A harsh 4-5 upshift ('01 Grand Cherokee only).** 3. **A harsh 5-4 downshift ('01 Grand Cherokee only).** NOTE: THIS REVISION TO THE TCM SOFTWARE ADDRESSES THE ABOVE SHIFT QUALITY CONDITIONS FOR ALL VEHICLES AND, ADDS A FINAL GEAR RATIO TO THE **1999 AND 2000 MY** GRAND CHEROKEE TRANSMISSION ONLY. (2001 MY GRAND CHEROKEE ALREADY HAS THIS UPGRADE.) NOTE: TO MAINTAIN EMISSIONS COMPLIANCE, GRAND CHEROKEE VEHICLES THAT ARE EQUIPPED WITH A FEDERAL EMISSION SYSTEM (SALES CODE NAA) MUST HAVE THEIR PCM REPROGRAMMED. IF THE SOFTWARE LEVEL IS AT OR HIGHER THAN THOSE IN THE OVERVIEW ABOVE, OR IF THE GRAND CHEROKEE HAS A CALIFORNIA EMISSIONS SYSTEM (SALES CODE NAE), REPROGRAMMING IS NOT NECESSARY. DIAGNOSIS PROCEDURES: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRBIII(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 performing this repair. If no DTC's are present, and the above symptom has been experienced, perform the Repair Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts > Page 4167 Procedure. NOTE: **IF OTHER PERFORMANCE ISSUES REMAIN AFTER THE REPAIR PROCEDURE HAS BEEN PERFORMED THEY DO NOT RELATE TO THIS BULLETIN. REFER TO THE PROPER SERVICE OR DIAGNOSTIC PROCEDURES MANUAL(S) FOR FURTHER ASSISTANCE.** PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD **2093 OR HIGHER AND DRB III(R) VERSION 52.3 WILL BE IN THE DEALERSHIPS ON OCTOBER 15, 2001.)** REPAIR PROCEDURE: 1. Log onto the MDS2 (Mopar Diagnostic System). 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III(R), MDS2, AND VEHICLE ESTABLISH COMMUNICATION. 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. 3. Push the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) 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. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. 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, 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 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts > Page 4168 7. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 8. 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > Page 4169 Transmission Control Module: Locations Fig. 13 Transmission Control Module Location The Transmission Control Module (TCM) is located in the engine compartment on the right (passenger) side and is mounted to the radiator core support. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions Transmission Control Module: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4172 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4173 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4174 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4175 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4176 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4177 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4178 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4179 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4180 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4181 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4182 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4183 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4184 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4185 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4186 Transmission Control Module: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4187 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4188 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4189 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4190 Transmission Control Module: Connector Views Transmission Control Module Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4191 Transmission Control Module Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4192 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 4193 Transmission Control Module: Description and Operation Fig. 13 Transmission Control Module Location The Transmission Control Module (TCM) is located in the engine compartment on the right (passenger) side and is mounted to the radiator core support (Fig. 13). The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hardwired to, and used specifically by the TCM. Indirect inputs originate from other components/modules, and are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - DRB Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 4194 - Transmission Temperature (to PCM) - PRNDL Position (to BCM) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with DRB scan tool) NOTE: If the TCM has been replaced, the "Quick Learn Procedure" must be performed. (Refer to ELECTRONIC CONTROL MODULES/ TRANSMISSION CONTROL MODULE - STANDARD PROCEDURE) Battery Feed A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain adaptive learn values in the TCM's RAM (Random Access Memory). When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. Clutch Volume Indexes (CVI) An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. Fig. 14 Example Of CVI Calculation By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur (Fig. 14). Gear ratios can be determined by using the DRB Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 4195 The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Clutch Volumes Certain mechanical problems within the input clutch assembly (broken return springs, out of position snap rings, excessive clutch pack clearance, improper assembly, etc.) can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following chart identifies the appropriate clutch volumes and when they are monitored/updated: Shift Schedules As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 4196 Driving Conditions As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 4197 Transmission Control Module: Service and Repair STANDARD PROCEDURES The quick learn procedure requires the use of the DRB scan tool. This program allows the electronic transmission system to recalibrate itself. This will provide the proper transmission operation. The quick learn procedure should be performed if any of the following procedures are performed: Transmission Assembly Replacement - Transmission Control Module Replacement - Solenoid Pack Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees. - The shift lever position must stay in PARK until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the DRB III indicates the procedure is complete - The calculated oil temperature must be above 60 ° and below 200 ° Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Transmission Control System Relay: Locations Power Distribution Center Transmission Control Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 4201 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 4202 Transmission Control System Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 4203 Transmission Control Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 4204 Transmission Control System Relay: Description and Operation DESCRIPTION The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. OPERATION When the relay is "off," no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Recalls for Control Module: > NHTSA01V077000 > Mar > 01 > Recall 01V077000: Transfer Case Control Module Problem Control Module: Recalls Recall 01V077000: Transfer Case Control Module Problem Vehicle Description: Light duty trucks and sport utility vehicles equipped with 4-wheel drive. The electric shift transfer case may not fully engage into gear when the operator moves the transfer case selector switch. This could cause the transfer case to end up in the neutral position unexpectedly and allow the vehicle to roll away if the parking brake is not applied. Dealers will reprogram the transfer case control module. Owner notification began April 9, 2001. 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 DaimlerChrysler at 1-800-853-1403. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > NHTSA01V077000 > Mar > 01 > Recall 01V077000: Transfer Case Control Module Problem Control Module: All Technical Service Bulletins Recall 01V077000: Transfer Case Control Module Problem Vehicle Description: Light duty trucks and sport utility vehicles equipped with 4-wheel drive. The electric shift transfer case may not fully engage into gear when the operator moves the transfer case selector switch. This could cause the transfer case to end up in the neutral position unexpectedly and allow the vehicle to roll away if the parking brake is not applied. Dealers will reprogram the transfer case control module. Owner notification began April 9, 2001. 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 DaimlerChrysler at 1-800-853-1403. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Service and Repair Fluid Pressure Sensor/Switch: Service and Repair LINE PRESSURE (LP) SENSOR REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pressure sensor (Fig. 81). 4. Remove the bolt holding the line pressure sensor to the transmission case. 5. Remove the line pressure sensor from the transmission case. INSTALLATION 1. Install the line pressure sensor into the transmission case. 2. Install the bolt to hold the line pressure sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 in. lbs.). 3. Install the wiring connector onto the line pressure sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 4227 Overdrive Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 4228 Overdrive Switch: Description and Operation DESCRIPTION The overdrive OFF (control) switch is located in the shift lever arm (Fig. 95). The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function. OPERATION At key-on, overdrive operation is allowed. Pressing the switch once causes the overdrive OFF mode to be entered and the overdrive OFF switch lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the overdrive lamp to be turned off. The overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the control switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4 upshift. The control switch indicator light illuminates only when the overdrive switch is turned to the OFF position, or when illuminated by the transmission control module. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 4229 Overdrive Switch: Service and Repair REMOVAL 1. Using a plastic trim tool, remove the overdrive off switch retainer from the shift lever (Fig. 96). 2. Pull the switch outwards to release it from the connector in the lever (Fig. 97) INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector out of the lever just enough to grasp it. CAUTION: Be careful not to bend the pins on the overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 4230 2. Install the overdrive off switch into the connector (Fig. 98) 3. Push the overdrive off switch and wiring into the shift lever. 4. Install the overdrive off switch retainer onto the shift lever. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Transmission Position Switch/Sensor: Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 4237 Transmission Position Switch/Sensor: Description and Operation DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has six switch contacts that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. - Supply ground to the TCM for backup lamp control in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > 42RE (A-500) 4 Speed Transmission Speed Sensor: Specifications Sensor, trans speed 20 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > 42RE (A-500) 4 Speed > Page 4242 Transmission Speed Sensor: Specifications Bolt, input speed sensor 105 in.lb Bolt, output speed sensor 105 in.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > 42RE (A-500) 4 Speed > Page 4243 Transmission Speed Sensor: Specifications Sensor, trans speed 20 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 4244 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor Input Speed Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor > Page 4247 Output Speed Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Input Speed Sensor Transmission Speed Sensor: Description and Operation Input Speed Sensor DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Input Speed Sensor > Page 4250 Transmission Speed Sensor: Description and Operation Output Speed Sensor OUTPUT SPEED SENSOR DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor Transmission Speed Sensor: Service and Repair Input Speed Sensor REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (Fig. 80). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor from the transmission case. INSTALLATION 1. Install the input speed sensor into the transmission case. 2. Install the bolt to hold the input speed sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the input speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor > Page 4253 Transmission Speed Sensor: Service and Repair Output Speed Sensor OUTPUT SPEED SENSOR REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor (Fig. 94). 4. Remove the bolt holding the output speed sensor to the transmission case. 5. Remove the output speed sensor from the transmission case. INSTALLATION 1. Install the output speed sensor into the transmission case. 2. Install the bolt to hold the output speed sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the output speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 4257 Transmission Temperature Sensor/Switch: Description and Operation DESCRIPTION The transmission temperature sensor is a thermistor that is integral to the Transmission Range Sensor (TRS). OPERATION The transmission temperature sensor is used by the TCM to sense the temperature of the fluid in the sump. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. Calculated Temperature A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Overdrive Switch, M/T > Component Information > Diagrams Overdrive Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Recalls for Control Module: > NHTSA01V077000 > Mar > 01 > Recall 01V077000: Transfer Case Control Module Problem Control Module: Recalls Recall 01V077000: Transfer Case Control Module Problem Vehicle Description: Light duty trucks and sport utility vehicles equipped with 4-wheel drive. The electric shift transfer case may not fully engage into gear when the operator moves the transfer case selector switch. This could cause the transfer case to end up in the neutral position unexpectedly and allow the vehicle to roll away if the parking brake is not applied. Dealers will reprogram the transfer case control module. Owner notification began April 9, 2001. 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 DaimlerChrysler at 1-800-853-1403. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > NHTSA01V077000 > Mar > 01 > Recall 01V077000: Transfer Case Control Module Problem Control Module: All Technical Service Bulletins Recall 01V077000: Transfer Case Control Module Problem Vehicle Description: Light duty trucks and sport utility vehicles equipped with 4-wheel drive. The electric shift transfer case may not fully engage into gear when the operator moves the transfer case selector switch. This could cause the transfer case to end up in the neutral position unexpectedly and allow the vehicle to roll away if the parking brake is not applied. Dealers will reprogram the transfer case control module. Owner notification began April 9, 2001. 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 DaimlerChrysler at 1-800-853-1403. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle Technical Service Bulletin # 08-032-00A Date: 001229 4X4 Service Lamp - ON, 4X2 Vehicle NUMBER: 08-032-00 REV. A GROUP: Electrical DATE: Dec. 29, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-032-00, DATED OCTOBER 20, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS BULLETIN IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS SUBJECT: "Service 4WD" Lamp Illuminated On 4X2 Vehicles OVERVIEW: This bulletin involves installing a revised HVAC control assembly. MODELS: NOTE: THIS BULLETIN APPLIES TO 4X2 VEHICLES BUILT BEFORE OCTOBER 13, 2000 (MDH 1013XX). SYMPTOM/CONDITION: The "Service 4WD" lamp is illuminated even though the truck is not a 4X4 vehicle. DIAGNOSIS: Start the engine. Once the instrument cluster bulb check has been completed, verify that the "Service 4WD" lamp is illuminated. If the "Service 4WD" lamp is illuminated, perform the Repair Procedure. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 4284 FAILURE CODE: Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING INSTRUMENT PANEL COMPONENT SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is equipped with an automatic transmission, turn the ignition switch to the Unlock position, set the park brake, and place the transmission gear selector lever in the LOW position. 3. If the vehicle is equipped with a tilt column, set the tilt steering column in its lowest position. 4. Reach under the left end of the instrument panel to access and unsnap the rod end clip on the park brake release link and disengage the link from the back of the handle (Fig. 1). 5. Remove the three screws that secure the lower edge of the steering column opening cover to the lower instrument panel reinforcement. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 4285 6. Using a trim stick or another suitable wide flat-bladed tool, gently pry the upper edge of the steering column opening cover just below the cluster bezel on each side of the steering column away from the instrument panel far enough to disengage each of the snap clip retainers from their receptacles in the instrument panel base trim (Fig. 2). 7. Remove the steering column opening cover from the instrument panel. 8. Remove the two screws in the hooded area above the instrument cluster that secures the cluster bezel to the instrument panel base trim (Fig. 3). 9. Using a trim stick or another suitable wide flat-bladed tool, gently pry around the perimeter of the cluster bezel to disengage the snap clips from their receptacles in the instrument panel base trim. 10. Pull the right side of the cluster bezel away from the instrument panel far enough to access and disconnect the instrument panel wire harness connector for the headlamp switch from the switch connector receptacle. 11. Pull the left side of the cluster bezel away from the instrument panel far enough to access and disconnect the instrument panel wire harness connectors from the receptacles for the passenger airbag ON/OFF switch (if equipped), the rear window defogger switch (if equipped), the HVAC control, and the transfer case switch (if equipped). 12. Remove the cluster bezel from the instrument panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 4286 13. Remove the four screws that secure the HVAC control to the cluster bezel (Fig. 4). 14. Remove the HVAC control from the instrument panel. 15. Position the new HVAC control (see Parts Required section) in the cluster bezel and secure it with four screws. Tighten the screws to 2.2 Nm (17 i3 in. lbs.) 16. Position the cluster bezel to the instrument panel. 17. Pull the left side of the cluster bezel away from the instrument panel far enough to access and reconnect the instrument panel wire harness connectors to the receptacles for the passenger airbag on/off switch (if equipped), the rear window defogger switch (if equipped), the HVAC control, and the transfer case switch (if equipped). 18. Pull the right side of the cluster bezel away from the instrument panel far enough to access and reconnect the instrument panel wire harness connector for the headlamp switch to the switch connector receptacle. 19. Align the snap clips on the cluster bezel with the receptacles in the instrument panel base trim. 20. Using hand pressure, press firmly on the cluster bezel over each of the snap clip locations until each snap clip is fully engaged in their receptacle. 21. Install and tighten the two screws in the hooded area above the instrument cluster that secure the cluster bezel to the instrument panel base trim (Fig. 3). Tighten the screws to 2.2 Nm (20 in. lbs.). 22. Position the steering column opening cover to the instrument panel. 23. Align the snap clip retainers on the steering column opening cover with the receptacles in the instrument panel base trim. 24. Using hand pressure, press firmly on the steering column opening cover over the snap clip locations until each of the snap clips are fully engaged in their receptacle. 25. Install and tighten the three screws that secure the lower edge of the steering column opening cover to the instrument structural support. Tighten the screws to 2.2 Nm (20 in.lbs.). 26. Reach under the left end of the instrument panel to access and engage the park brake release link to the back of the handle. Then snap the rod end clip over the park brake release link to secure the connection. 27. Reconnect the battery negative cable. 28. On vehicles equipped with A/C, perform the A/C cool down test using the DRBIII(R). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle Technical Service Bulletin # 08-032-00A Date: 001229 4X4 Service Lamp - ON, 4X2 Vehicle NUMBER: 08-032-00 REV. A GROUP: Electrical DATE: Dec. 29, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-032-00, DATED OCTOBER 20, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS BULLETIN IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS SUBJECT: "Service 4WD" Lamp Illuminated On 4X2 Vehicles OVERVIEW: This bulletin involves installing a revised HVAC control assembly. MODELS: NOTE: THIS BULLETIN APPLIES TO 4X2 VEHICLES BUILT BEFORE OCTOBER 13, 2000 (MDH 1013XX). SYMPTOM/CONDITION: The "Service 4WD" lamp is illuminated even though the truck is not a 4X4 vehicle. DIAGNOSIS: Start the engine. Once the instrument cluster bulb check has been completed, verify that the "Service 4WD" lamp is illuminated. If the "Service 4WD" lamp is illuminated, perform the Repair Procedure. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 4292 FAILURE CODE: Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING INSTRUMENT PANEL COMPONENT SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is equipped with an automatic transmission, turn the ignition switch to the Unlock position, set the park brake, and place the transmission gear selector lever in the LOW position. 3. If the vehicle is equipped with a tilt column, set the tilt steering column in its lowest position. 4. Reach under the left end of the instrument panel to access and unsnap the rod end clip on the park brake release link and disengage the link from the back of the handle (Fig. 1). 5. Remove the three screws that secure the lower edge of the steering column opening cover to the lower instrument panel reinforcement. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 4293 6. Using a trim stick or another suitable wide flat-bladed tool, gently pry the upper edge of the steering column opening cover just below the cluster bezel on each side of the steering column away from the instrument panel far enough to disengage each of the snap clip retainers from their receptacles in the instrument panel base trim (Fig. 2). 7. Remove the steering column opening cover from the instrument panel. 8. Remove the two screws in the hooded area above the instrument cluster that secures the cluster bezel to the instrument panel base trim (Fig. 3). 9. Using a trim stick or another suitable wide flat-bladed tool, gently pry around the perimeter of the cluster bezel to disengage the snap clips from their receptacles in the instrument panel base trim. 10. Pull the right side of the cluster bezel away from the instrument panel far enough to access and disconnect the instrument panel wire harness connector for the headlamp switch from the switch connector receptacle. 11. Pull the left side of the cluster bezel away from the instrument panel far enough to access and disconnect the instrument panel wire harness connectors from the receptacles for the passenger airbag ON/OFF switch (if equipped), the rear window defogger switch (if equipped), the HVAC control, and the transfer case switch (if equipped). 12. Remove the cluster bezel from the instrument panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 4294 13. Remove the four screws that secure the HVAC control to the cluster bezel (Fig. 4). 14. Remove the HVAC control from the instrument panel. 15. Position the new HVAC control (see Parts Required section) in the cluster bezel and secure it with four screws. Tighten the screws to 2.2 Nm (17 i3 in. lbs.) 16. Position the cluster bezel to the instrument panel. 17. Pull the left side of the cluster bezel away from the instrument panel far enough to access and reconnect the instrument panel wire harness connectors to the receptacles for the passenger airbag on/off switch (if equipped), the rear window defogger switch (if equipped), the HVAC control, and the transfer case switch (if equipped). 18. Pull the right side of the cluster bezel away from the instrument panel far enough to access and reconnect the instrument panel wire harness connector for the headlamp switch to the switch connector receptacle. 19. Align the snap clips on the cluster bezel with the receptacles in the instrument panel base trim. 20. Using hand pressure, press firmly on the cluster bezel over each of the snap clip locations until each snap clip is fully engaged in their receptacle. 21. Install and tighten the two screws in the hooded area above the instrument cluster that secure the cluster bezel to the instrument panel base trim (Fig. 3). Tighten the screws to 2.2 Nm (20 in. lbs.). 22. Position the steering column opening cover to the instrument panel. 23. Align the snap clip retainers on the steering column opening cover with the receptacles in the instrument panel base trim. 24. Using hand pressure, press firmly on the steering column opening cover over the snap clip locations until each of the snap clips are fully engaged in their receptacle. 25. Install and tighten the three screws that secure the lower edge of the steering column opening cover to the instrument structural support. Tighten the screws to 2.2 Nm (20 in.lbs.). 26. Reach under the left end of the instrument panel to access and engage the park brake release link to the back of the handle. Then snap the rod end clip over the park brake release link to secure the connection. 27. Reconnect the battery negative cable. 28. On vehicles equipped with A/C, perform the A/C cool down test using the DRBIII(R). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle Technical Service Bulletin # 08-032-00A Date: 001229 4X4 Service Lamp - ON, 4X2 Vehicle NUMBER: 08-032-00 REV. A GROUP: Electrical DATE: Dec. 29, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-032-00, DATED OCTOBER 20, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS BULLETIN IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS SUBJECT: "Service 4WD" Lamp Illuminated On 4X2 Vehicles OVERVIEW: This bulletin involves installing a revised HVAC control assembly. MODELS: NOTE: THIS BULLETIN APPLIES TO 4X2 VEHICLES BUILT BEFORE OCTOBER 13, 2000 (MDH 1013XX). SYMPTOM/CONDITION: The "Service 4WD" lamp is illuminated even though the truck is not a 4X4 vehicle. DIAGNOSIS: Start the engine. Once the instrument cluster bulb check has been completed, verify that the "Service 4WD" lamp is illuminated. If the "Service 4WD" lamp is illuminated, perform the Repair Procedure. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 4304 FAILURE CODE: Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING INSTRUMENT PANEL COMPONENT SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is equipped with an automatic transmission, turn the ignition switch to the Unlock position, set the park brake, and place the transmission gear selector lever in the LOW position. 3. If the vehicle is equipped with a tilt column, set the tilt steering column in its lowest position. 4. Reach under the left end of the instrument panel to access and unsnap the rod end clip on the park brake release link and disengage the link from the back of the handle (Fig. 1). 5. Remove the three screws that secure the lower edge of the steering column opening cover to the lower instrument panel reinforcement. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 4305 6. Using a trim stick or another suitable wide flat-bladed tool, gently pry the upper edge of the steering column opening cover just below the cluster bezel on each side of the steering column away from the instrument panel far enough to disengage each of the snap clip retainers from their receptacles in the instrument panel base trim (Fig. 2). 7. Remove the steering column opening cover from the instrument panel. 8. Remove the two screws in the hooded area above the instrument cluster that secures the cluster bezel to the instrument panel base trim (Fig. 3). 9. Using a trim stick or another suitable wide flat-bladed tool, gently pry around the perimeter of the cluster bezel to disengage the snap clips from their receptacles in the instrument panel base trim. 10. Pull the right side of the cluster bezel away from the instrument panel far enough to access and disconnect the instrument panel wire harness connector for the headlamp switch from the switch connector receptacle. 11. Pull the left side of the cluster bezel away from the instrument panel far enough to access and disconnect the instrument panel wire harness connectors from the receptacles for the passenger airbag ON/OFF switch (if equipped), the rear window defogger switch (if equipped), the HVAC control, and the transfer case switch (if equipped). 12. Remove the cluster bezel from the instrument panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 4306 13. Remove the four screws that secure the HVAC control to the cluster bezel (Fig. 4). 14. Remove the HVAC control from the instrument panel. 15. Position the new HVAC control (see Parts Required section) in the cluster bezel and secure it with four screws. Tighten the screws to 2.2 Nm (17 i3 in. lbs.) 16. Position the cluster bezel to the instrument panel. 17. Pull the left side of the cluster bezel away from the instrument panel far enough to access and reconnect the instrument panel wire harness connectors to the receptacles for the passenger airbag on/off switch (if equipped), the rear window defogger switch (if equipped), the HVAC control, and the transfer case switch (if equipped). 18. Pull the right side of the cluster bezel away from the instrument panel far enough to access and reconnect the instrument panel wire harness connector for the headlamp switch to the switch connector receptacle. 19. Align the snap clips on the cluster bezel with the receptacles in the instrument panel base trim. 20. Using hand pressure, press firmly on the cluster bezel over each of the snap clip locations until each snap clip is fully engaged in their receptacle. 21. Install and tighten the two screws in the hooded area above the instrument cluster that secure the cluster bezel to the instrument panel base trim (Fig. 3). Tighten the screws to 2.2 Nm (20 in. lbs.). 22. Position the steering column opening cover to the instrument panel. 23. Align the snap clip retainers on the steering column opening cover with the receptacles in the instrument panel base trim. 24. Using hand pressure, press firmly on the steering column opening cover over the snap clip locations until each of the snap clips are fully engaged in their receptacle. 25. Install and tighten the three screws that secure the lower edge of the steering column opening cover to the instrument structural support. Tighten the screws to 2.2 Nm (20 in.lbs.). 26. Reach under the left end of the instrument panel to access and engage the park brake release link to the back of the handle. Then snap the rod end clip over the park brake release link to secure the connection. 27. Reconnect the battery negative cable. 28. On vehicles equipped with A/C, perform the A/C cool down test using the DRBIII(R). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle Technical Service Bulletin # 08-032-00A Date: 001229 4X4 Service Lamp - ON, 4X2 Vehicle NUMBER: 08-032-00 REV. A GROUP: Electrical DATE: Dec. 29, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-032-00, DATED OCTOBER 20, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS BULLETIN IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS SUBJECT: "Service 4WD" Lamp Illuminated On 4X2 Vehicles OVERVIEW: This bulletin involves installing a revised HVAC control assembly. MODELS: NOTE: THIS BULLETIN APPLIES TO 4X2 VEHICLES BUILT BEFORE OCTOBER 13, 2000 (MDH 1013XX). SYMPTOM/CONDITION: The "Service 4WD" lamp is illuminated even though the truck is not a 4X4 vehicle. DIAGNOSIS: Start the engine. Once the instrument cluster bulb check has been completed, verify that the "Service 4WD" lamp is illuminated. If the "Service 4WD" lamp is illuminated, perform the Repair Procedure. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 4312 FAILURE CODE: Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING INSTRUMENT PANEL COMPONENT SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is equipped with an automatic transmission, turn the ignition switch to the Unlock position, set the park brake, and place the transmission gear selector lever in the LOW position. 3. If the vehicle is equipped with a tilt column, set the tilt steering column in its lowest position. 4. Reach under the left end of the instrument panel to access and unsnap the rod end clip on the park brake release link and disengage the link from the back of the handle (Fig. 1). 5. Remove the three screws that secure the lower edge of the steering column opening cover to the lower instrument panel reinforcement. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 4313 6. Using a trim stick or another suitable wide flat-bladed tool, gently pry the upper edge of the steering column opening cover just below the cluster bezel on each side of the steering column away from the instrument panel far enough to disengage each of the snap clip retainers from their receptacles in the instrument panel base trim (Fig. 2). 7. Remove the steering column opening cover from the instrument panel. 8. Remove the two screws in the hooded area above the instrument cluster that secures the cluster bezel to the instrument panel base trim (Fig. 3). 9. Using a trim stick or another suitable wide flat-bladed tool, gently pry around the perimeter of the cluster bezel to disengage the snap clips from their receptacles in the instrument panel base trim. 10. Pull the right side of the cluster bezel away from the instrument panel far enough to access and disconnect the instrument panel wire harness connector for the headlamp switch from the switch connector receptacle. 11. Pull the left side of the cluster bezel away from the instrument panel far enough to access and disconnect the instrument panel wire harness connectors from the receptacles for the passenger airbag ON/OFF switch (if equipped), the rear window defogger switch (if equipped), the HVAC control, and the transfer case switch (if equipped). 12. Remove the cluster bezel from the instrument panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 4314 13. Remove the four screws that secure the HVAC control to the cluster bezel (Fig. 4). 14. Remove the HVAC control from the instrument panel. 15. Position the new HVAC control (see Parts Required section) in the cluster bezel and secure it with four screws. Tighten the screws to 2.2 Nm (17 i3 in. lbs.) 16. Position the cluster bezel to the instrument panel. 17. Pull the left side of the cluster bezel away from the instrument panel far enough to access and reconnect the instrument panel wire harness connectors to the receptacles for the passenger airbag on/off switch (if equipped), the rear window defogger switch (if equipped), the HVAC control, and the transfer case switch (if equipped). 18. Pull the right side of the cluster bezel away from the instrument panel far enough to access and reconnect the instrument panel wire harness connector for the headlamp switch to the switch connector receptacle. 19. Align the snap clips on the cluster bezel with the receptacles in the instrument panel base trim. 20. Using hand pressure, press firmly on the cluster bezel over each of the snap clip locations until each snap clip is fully engaged in their receptacle. 21. Install and tighten the two screws in the hooded area above the instrument cluster that secure the cluster bezel to the instrument panel base trim (Fig. 3). Tighten the screws to 2.2 Nm (20 in. lbs.). 22. Position the steering column opening cover to the instrument panel. 23. Align the snap clip retainers on the steering column opening cover with the receptacles in the instrument panel base trim. 24. Using hand pressure, press firmly on the steering column opening cover over the snap clip locations until each of the snap clips are fully engaged in their receptacle. 25. Install and tighten the three screws that secure the lower edge of the steering column opening cover to the instrument structural support. Tighten the screws to 2.2 Nm (20 in.lbs.). 26. Reach under the left end of the instrument panel to access and engage the park brake release link to the back of the handle. Then snap the rod end clip over the park brake release link to secure the connection. 27. Reconnect the battery negative cable. 28. On vehicles equipped with A/C, perform the A/C cool down test using the DRBIII(R). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Recalls for Control Module: > NHTSA01V077000 > Mar > 01 > Recall 01V077000: Transfer Case Control Module Problem Control Module: Recalls Recall 01V077000: Transfer Case Control Module Problem Vehicle Description: Light duty trucks and sport utility vehicles equipped with 4-wheel drive. The electric shift transfer case may not fully engage into gear when the operator moves the transfer case selector switch. This could cause the transfer case to end up in the neutral position unexpectedly and allow the vehicle to roll away if the parking brake is not applied. Dealers will reprogram the transfer case control module. Owner notification began April 9, 2001. 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 DaimlerChrysler at 1-800-853-1403. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > NHTSA01V077000 > Mar > 01 > Recall 01V077000: Transfer Case Control Module Problem Control Module: All Technical Service Bulletins Recall 01V077000: Transfer Case Control Module Problem Vehicle Description: Light duty trucks and sport utility vehicles equipped with 4-wheel drive. The electric shift transfer case may not fully engage into gear when the operator moves the transfer case selector switch. This could cause the transfer case to end up in the neutral position unexpectedly and allow the vehicle to roll away if the parking brake is not applied. Dealers will reprogram the transfer case control module. Owner notification began April 9, 2001. 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 DaimlerChrysler at 1-800-853-1403. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Service and Repair Shift Solenoid: Service and Repair REMOVAL 1. Remove the valve body from the transmission (Fig. 116). 2. Remove the screws holding the transmission solenoid/TRS assembly onto the valve body (Fig. 117). 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the screws to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 5.7 Nm (50 inch lbs.). 5. Tighten the remainder of the solenoid assembly screws to 5.7 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance Torque Converter Clutch Solenoid: Customer Interest MIL ON - TCC/OD Solenoid Performance NUMBER: 21-11-00 GROUP: Transmissions EFFECTIVE DATE: October 02, 2000 SUBJECT: 46RE Transmission MIL Due To DTC P1740 - TCC or OD Solenoid Performance OVERVIEW: This bulletin involves the replacement of the transmission pressure boost valve cover plate. MODELS: 2000 - 2001 (AB) Ram Van 2000 - 2001 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 - 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 46RE TRANSMISSION BUILT BEFORE AUGUST 01, 2000 (MDH O8O1XX). SYMPTOM/CONDITION: The customer may complain of a Malfunction Indicator Lamp (MIL) illumination. Upon further analysis, it is determined that the MIL is caused by Diagnostic Trouble Code (DTC) P1740 - Torque Converter Clutch (TCC) or Overdrive Solenoid Performance. Other than the MIL, the customer may not notice any other condition with the transmission. This condition may be caused by an intermittent and momentary TCC disengagement condition. The transmission valve body pressure boost valve cover plate has been revised with a larger size orifice hole to address this condition. DIAGNOSIS: 1. Warm the transmission to normal operating temperatures. 2. Using the DRB III(R), perform a torque converter clutch (TCC) stall test. The stall test has been revised so that the TCC remains engaged for a period of four (4) seconds. NOTE: THE DRB III(R) MUST BE OPERATING AT RELEASE LEVEL 50.4 MDS2 SYSTEM CIS CD2067 OR HIGHER (AVAILABLE THE WEEK OF OCTOBER 2, 2000) IN ORDER TO PERFORM THE REVISED TORQUE CONVERTER CLUTCH STALL TEST. DO NOT USE EARLIER VERSION STALL TEST TO DETERMINE CONDITION OF THE TORQUE CONVERTER CLUTCH. 3. If the engine stalls as a result of the TCC stall test, then perform the Repair Procedure. 4. If the engine does not stall, as a result of the TCC stall test, then further diagnosis is required. The technician may want to consider the following components during their additional diagnosis: a cut or worn input shaft seals, a missing pump lock-up circuit check ball, or worn converter hub, input shaft, reaction shaft, and pump rotor. PARTS REQUIRED: REPAIR PROCEDURE: 1. Clean the pressure boost valve cover plate to remove any dirt or rust inhibitor prior to installation. The revised cover plate will have a 1.75 mm (0.069 inch) orifice hole versus a 1.22 mm (0.048 inch) orifice hole in the original plate. Make sure it is clean. 2. Using the appropriate Service Manual, Group 21 - Transmissions and Transfer Case, replace the transmission pressure boost valve cover plate p/n Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance > Page 4346 04617012. 3. Verify fluid level after warming up the transmission and cycling the shift lever several times. 4. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance Torque Converter Clutch Solenoid: All Technical Service Bulletins MIL ON - TCC/OD Solenoid Performance NUMBER: 21-11-00 GROUP: Transmissions EFFECTIVE DATE: October 02, 2000 SUBJECT: 46RE Transmission MIL Due To DTC P1740 - TCC or OD Solenoid Performance OVERVIEW: This bulletin involves the replacement of the transmission pressure boost valve cover plate. MODELS: 2000 - 2001 (AB) Ram Van 2000 - 2001 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 - 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 46RE TRANSMISSION BUILT BEFORE AUGUST 01, 2000 (MDH O8O1XX). SYMPTOM/CONDITION: The customer may complain of a Malfunction Indicator Lamp (MIL) illumination. Upon further analysis, it is determined that the MIL is caused by Diagnostic Trouble Code (DTC) P1740 - Torque Converter Clutch (TCC) or Overdrive Solenoid Performance. Other than the MIL, the customer may not notice any other condition with the transmission. This condition may be caused by an intermittent and momentary TCC disengagement condition. The transmission valve body pressure boost valve cover plate has been revised with a larger size orifice hole to address this condition. DIAGNOSIS: 1. Warm the transmission to normal operating temperatures. 2. Using the DRB III(R), perform a torque converter clutch (TCC) stall test. The stall test has been revised so that the TCC remains engaged for a period of four (4) seconds. NOTE: THE DRB III(R) MUST BE OPERATING AT RELEASE LEVEL 50.4 MDS2 SYSTEM CIS CD2067 OR HIGHER (AVAILABLE THE WEEK OF OCTOBER 2, 2000) IN ORDER TO PERFORM THE REVISED TORQUE CONVERTER CLUTCH STALL TEST. DO NOT USE EARLIER VERSION STALL TEST TO DETERMINE CONDITION OF THE TORQUE CONVERTER CLUTCH. 3. If the engine stalls as a result of the TCC stall test, then perform the Repair Procedure. 4. If the engine does not stall, as a result of the TCC stall test, then further diagnosis is required. The technician may want to consider the following components during their additional diagnosis: a cut or worn input shaft seals, a missing pump lock-up circuit check ball, or worn converter hub, input shaft, reaction shaft, and pump rotor. PARTS REQUIRED: REPAIR PROCEDURE: 1. Clean the pressure boost valve cover plate to remove any dirt or rust inhibitor prior to installation. The revised cover plate will have a 1.75 mm (0.069 inch) orifice hole versus a 1.22 mm (0.048 inch) orifice hole in the original plate. Make sure it is clean. 2. Using the appropriate Service Manual, Group 21 - Transmissions and Transfer Case, replace the transmission pressure boost valve cover plate p/n Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance > Page 4352 04617012. 3. Verify fluid level after warming up the transmission and cycling the shift lever several times. 4. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Technical Service Bulletins > Page 4353 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Overdrive Indicator Lamp: Locations The Overdrive OFF Indicator (VFD) is part of the cluster electronic circuit board, and is visible through a cutout located in the lower right corner of the cluster overlay. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 4359 Overdrive Indicator Lamp: Description and Operation OVERDRIVE OFF INDICATOR An overdrive OFF indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional overdrive automatic transmission, this indicator is electronically disabled. The overdrive OFF indicator consists of the text "O/D OFF", which appears in the lower portion of the electronic gear selector indicator Vacuum Fluorescent Display (VFD). The VFD is part of the cluster electronic circuit board, and is visible through a cutout located in the lower right corner of the cluster overlay. The dark lens of the VFD prevents the indicator from being clearly visible when it is not illuminated. The text "O/D OFF" appears in an amber color and at the same lighting level as the gear selector indicator information when it is illuminated by the instrument cluster electronic circuit board. The overdrive OFF indicator is serviced as a unit with the VFD in the instrument cluster. The overdrive OFF indicator gives an indication to the vehicle operator when the OFF position of the overdrive OFF switch has been selected, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The overdrive OFF indicator receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions; therefore, the indicator will always be OFF when the ignition switch is in any position except ON or Start. The indicator only illuminates when it is switched to ground by the instrument cluster circuitry. The instrument cluster will turn ON the overdrive OFF indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the overdrive OFF indicator is illuminated for about two seconds as a bulb test. - Overdrive OFF Lamp-ON Message - Each time the cluster receives an overdrive OFF lamp-ON message from the PCM indicating that the OFF position of the overdrive OFF switch has been selected, the overdrive OFF indicator will be illuminated. The indicator remains illuminated until the cluster receives an overdrive OFF lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the overdrive OFF indicator will be turned ON, then OFF again during the VFD portion of the test to confirm the functionality of the VFD, and again during the bulb check portion of the test to confirm the functionality of the cluster control circuitry. The PCM continually monitors the overdrive OFF switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper overdrive OFF lamp-ON and lamp-OFF messages to the instrument cluster. For further diagnosis of the overdrive OFF indicator or the instrument cluster circuitry that controls the indicator, (Refer to INSTRUMENT/CLUSTER DIAGNOSIS AND TESTING). For proper diagnosis of the overdrive control system, the PCM, the PCI data bus, or the message inputs to the instrument cluster that control the overdrive OFF indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair Shift Indicator: Service and Repair GEARSHIFT INDICATOR REMOVAL The following service procedures apply only to the mechanical gear selector indicator. The electronic gear selector indicator is integral to the instrument cluster and can only be serviced by replacement of the instrument cluster unit. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument cluster from the instrument panel. Fig. 13 3. Remove the two screws that secure the gear selector indicator mechanism to the back of the instrument cluster housing (Fig. 13). 4. Remove the gear selector indicator mechanism from the back of the instrument cluster housing. 5. Remove the steering column opening cover from the instrument panel. Fig. 14 6. Disengage the loop end of the gear selector indicator cable from the lever on the left side of the steering column (Fig. 14). 7. Squeeze the sides of the plastic adjuster and bracket unit to disengage the tabs that secure it to the sides of the steering column window. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair > Page 4363 8. Remove the gear selector indicator mechanism and cable unit from the instrument panel. INSTALLATION The following service procedures apply only to the mechanical gear selector indicator. The electronic gear selector indicator is integral to the instrument cluster and can only be serviced by replacement of the instrument cluster unit. 1. Position the gear selector indicator mechanism and cable unit to the instrument panel. 2. Squeeze the sides of the plastic adjuster and bracket unit and engage the tabs that secure it with the sides of the steering column window. 3. Engage the loop end of the gear selector indicator cable onto the lever on the left side of the steering column (Fig. 14). 4. Position the gear selector indicator mechanism onto the back of the instrument cluster housing. 5. Install and tighten the two screws that secure the gear selector indicator mechanism to the back of the instrument cluster housing. Tighten the screws to 2.2 N.m (20 in. lbs.). 6. Install the instrument cluster onto the instrument panel. 7. Check the gear selector indicator for proper calibration. If adjustment is needed, 8. Install the steering column opening cover onto the instrument panel. 9. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Locations Temperature Warning Indicator - A/T: Locations The transmission over-temperature indicator is located in the Information Center area of the instrument cluster, to the left of center. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Locations > Page 4367 Temperature Warning Indicator - A/T: Description and Operation A transmission over-temperature indicator lamp is standard equipment on all instrument clusters. The transmission over-temperature indicator is located in the Information Center area of the instrument cluster, to the left of center. The transmission over-temperature indicator consists of a stencilled cutout of the words "TRANS TEMP" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red lens behind the cutout in the opaque layer of the overlay causes the "TRANS TEMP" text to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by a Light Emitting Diode (LED) soldered onto the instrument cluster electronic circuit board. The transmission overtemperature indicator is serviced as a unit with the instrument cluster. The transmission over-temperature indicator gives an indication to the vehicle operator when the trans- mission fluid temperature is excessive, which may lead to accelerated transmission component wear or failure. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The transmission over-temperature indicator Light Emitting Diode (LED) receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions; therefore, the LED will always be OFF when the ignition switch is in any position except ON or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the transmission over-temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the transmission over-temperature indicator is illuminated for about two seconds as a bulb test. - Trans Over-Temp Lamp-ON Message - Each time the cluster receives a trans over-temp lamp-ON message from the PCM indicating that the transmission fluid temperature is 135 °C (275 °F) or higher, the indicator will be illuminated and a single chime tone is sounded. The lamp remains illuminated until the cluster receives a trans over-temp lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the transmission over-temperature indicator is cycled OFF and then on again by the appropriate trans over-temp messages from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition, then sends the proper messages to the instrument cluster. If the instrument cluster turns ON the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission and/or the transmission cooling system are being overloaded or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the transmission temperature sensor, the PCM, the PCI data bus, or the message inputs to the instrument cluster that control the transmission over-temperature indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle Technical Service Bulletin # 08-032-00A Date: 001229 4X4 Service Lamp - ON, 4X2 Vehicle NUMBER: 08-032-00 REV. A GROUP: Electrical DATE: Dec. 29, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-032-00, DATED OCTOBER 20, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS BULLETIN IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS SUBJECT: "Service 4WD" Lamp Illuminated On 4X2 Vehicles OVERVIEW: This bulletin involves installing a revised HVAC control assembly. MODELS: NOTE: THIS BULLETIN APPLIES TO 4X2 VEHICLES BUILT BEFORE OCTOBER 13, 2000 (MDH 1013XX). SYMPTOM/CONDITION: The "Service 4WD" lamp is illuminated even though the truck is not a 4X4 vehicle. DIAGNOSIS: Start the engine. Once the instrument cluster bulb check has been completed, verify that the "Service 4WD" lamp is illuminated. If the "Service 4WD" lamp is illuminated, perform the Repair Procedure. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 4377 FAILURE CODE: Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING INSTRUMENT PANEL COMPONENT SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is equipped with an automatic transmission, turn the ignition switch to the Unlock position, set the park brake, and place the transmission gear selector lever in the LOW position. 3. If the vehicle is equipped with a tilt column, set the tilt steering column in its lowest position. 4. Reach under the left end of the instrument panel to access and unsnap the rod end clip on the park brake release link and disengage the link from the back of the handle (Fig. 1). 5. Remove the three screws that secure the lower edge of the steering column opening cover to the lower instrument panel reinforcement. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 4378 6. Using a trim stick or another suitable wide flat-bladed tool, gently pry the upper edge of the steering column opening cover just below the cluster bezel on each side of the steering column away from the instrument panel far enough to disengage each of the snap clip retainers from their receptacles in the instrument panel base trim (Fig. 2). 7. Remove the steering column opening cover from the instrument panel. 8. Remove the two screws in the hooded area above the instrument cluster that secures the cluster bezel to the instrument panel base trim (Fig. 3). 9. Using a trim stick or another suitable wide flat-bladed tool, gently pry around the perimeter of the cluster bezel to disengage the snap clips from their receptacles in the instrument panel base trim. 10. Pull the right side of the cluster bezel away from the instrument panel far enough to access and disconnect the instrument panel wire harness connector for the headlamp switch from the switch connector receptacle. 11. Pull the left side of the cluster bezel away from the instrument panel far enough to access and disconnect the instrument panel wire harness connectors from the receptacles for the passenger airbag ON/OFF switch (if equipped), the rear window defogger switch (if equipped), the HVAC control, and the transfer case switch (if equipped). 12. Remove the cluster bezel from the instrument panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 4379 13. Remove the four screws that secure the HVAC control to the cluster bezel (Fig. 4). 14. Remove the HVAC control from the instrument panel. 15. Position the new HVAC control (see Parts Required section) in the cluster bezel and secure it with four screws. Tighten the screws to 2.2 Nm (17 i3 in. lbs.) 16. Position the cluster bezel to the instrument panel. 17. Pull the left side of the cluster bezel away from the instrument panel far enough to access and reconnect the instrument panel wire harness connectors to the receptacles for the passenger airbag on/off switch (if equipped), the rear window defogger switch (if equipped), the HVAC control, and the transfer case switch (if equipped). 18. Pull the right side of the cluster bezel away from the instrument panel far enough to access and reconnect the instrument panel wire harness connector for the headlamp switch to the switch connector receptacle. 19. Align the snap clips on the cluster bezel with the receptacles in the instrument panel base trim. 20. Using hand pressure, press firmly on the cluster bezel over each of the snap clip locations until each snap clip is fully engaged in their receptacle. 21. Install and tighten the two screws in the hooded area above the instrument cluster that secure the cluster bezel to the instrument panel base trim (Fig. 3). Tighten the screws to 2.2 Nm (20 in. lbs.). 22. Position the steering column opening cover to the instrument panel. 23. Align the snap clip retainers on the steering column opening cover with the receptacles in the instrument panel base trim. 24. Using hand pressure, press firmly on the steering column opening cover over the snap clip locations until each of the snap clips are fully engaged in their receptacle. 25. Install and tighten the three screws that secure the lower edge of the steering column opening cover to the instrument structural support. Tighten the screws to 2.2 Nm (20 in.lbs.). 26. Reach under the left end of the instrument panel to access and engage the park brake release link to the back of the handle. Then snap the rod end clip over the park brake release link to secure the connection. 27. Reconnect the battery negative cable. 28. On vehicles equipped with A/C, perform the A/C cool down test using the DRBIII(R). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle Technical Service Bulletin # 08-032-00A Date: 001229 4X4 Service Lamp - ON, 4X2 Vehicle NUMBER: 08-032-00 REV. A GROUP: Electrical DATE: Dec. 29, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-032-00, DATED OCTOBER 20, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS BULLETIN IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS SUBJECT: "Service 4WD" Lamp Illuminated On 4X2 Vehicles OVERVIEW: This bulletin involves installing a revised HVAC control assembly. MODELS: NOTE: THIS BULLETIN APPLIES TO 4X2 VEHICLES BUILT BEFORE OCTOBER 13, 2000 (MDH 1013XX). SYMPTOM/CONDITION: The "Service 4WD" lamp is illuminated even though the truck is not a 4X4 vehicle. DIAGNOSIS: Start the engine. Once the instrument cluster bulb check has been completed, verify that the "Service 4WD" lamp is illuminated. If the "Service 4WD" lamp is illuminated, perform the Repair Procedure. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 4385 FAILURE CODE: Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING INSTRUMENT PANEL COMPONENT SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is equipped with an automatic transmission, turn the ignition switch to the Unlock position, set the park brake, and place the transmission gear selector lever in the LOW position. 3. If the vehicle is equipped with a tilt column, set the tilt steering column in its lowest position. 4. Reach under the left end of the instrument panel to access and unsnap the rod end clip on the park brake release link and disengage the link from the back of the handle (Fig. 1). 5. Remove the three screws that secure the lower edge of the steering column opening cover to the lower instrument panel reinforcement. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 4386 6. Using a trim stick or another suitable wide flat-bladed tool, gently pry the upper edge of the steering column opening cover just below the cluster bezel on each side of the steering column away from the instrument panel far enough to disengage each of the snap clip retainers from their receptacles in the instrument panel base trim (Fig. 2). 7. Remove the steering column opening cover from the instrument panel. 8. Remove the two screws in the hooded area above the instrument cluster that secures the cluster bezel to the instrument panel base trim (Fig. 3). 9. Using a trim stick or another suitable wide flat-bladed tool, gently pry around the perimeter of the cluster bezel to disengage the snap clips from their receptacles in the instrument panel base trim. 10. Pull the right side of the cluster bezel away from the instrument panel far enough to access and disconnect the instrument panel wire harness connector for the headlamp switch from the switch connector receptacle. 11. Pull the left side of the cluster bezel away from the instrument panel far enough to access and disconnect the instrument panel wire harness connectors from the receptacles for the passenger airbag ON/OFF switch (if equipped), the rear window defogger switch (if equipped), the HVAC control, and the transfer case switch (if equipped). 12. Remove the cluster bezel from the instrument panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 4387 13. Remove the four screws that secure the HVAC control to the cluster bezel (Fig. 4). 14. Remove the HVAC control from the instrument panel. 15. Position the new HVAC control (see Parts Required section) in the cluster bezel and secure it with four screws. Tighten the screws to 2.2 Nm (17 i3 in. lbs.) 16. Position the cluster bezel to the instrument panel. 17. Pull the left side of the cluster bezel away from the instrument panel far enough to access and reconnect the instrument panel wire harness connectors to the receptacles for the passenger airbag on/off switch (if equipped), the rear window defogger switch (if equipped), the HVAC control, and the transfer case switch (if equipped). 18. Pull the right side of the cluster bezel away from the instrument panel far enough to access and reconnect the instrument panel wire harness connector for the headlamp switch to the switch connector receptacle. 19. Align the snap clips on the cluster bezel with the receptacles in the instrument panel base trim. 20. Using hand pressure, press firmly on the cluster bezel over each of the snap clip locations until each snap clip is fully engaged in their receptacle. 21. Install and tighten the two screws in the hooded area above the instrument cluster that secure the cluster bezel to the instrument panel base trim (Fig. 3). Tighten the screws to 2.2 Nm (20 in. lbs.). 22. Position the steering column opening cover to the instrument panel. 23. Align the snap clip retainers on the steering column opening cover with the receptacles in the instrument panel base trim. 24. Using hand pressure, press firmly on the steering column opening cover over the snap clip locations until each of the snap clips are fully engaged in their receptacle. 25. Install and tighten the three screws that secure the lower edge of the steering column opening cover to the instrument structural support. Tighten the screws to 2.2 Nm (20 in.lbs.). 26. Reach under the left end of the instrument panel to access and engage the park brake release link to the back of the handle. Then snap the rod end clip over the park brake release link to secure the connection. 27. Reconnect the battery negative cable. 28. On vehicles equipped with A/C, perform the A/C cool down test using the DRBIII(R). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > Customer Interest for Transmission Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts Transmission Control Module: Customer Interest A/T - 45RFE/545RFE Harsh Upshifts/Downshifts NUMBER: 18-025-01 GROUP: Vehicle Performance DATE: October 15, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-09-00, DATED SEPTEMBER 15, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. **ASTERISKS** HAVE BEEN USED TO HIGHLIGHT CHANGES. THIS BULLETIN ADDS A MODEL YEAR AND REQUIRES A REPROGRAMMING OF THE 1999 AND 2000 GRAND CHEROKEE POWERTRAIN CONTROL MODULE (PCM). SUBJECT: 45RFE **and 545RFE Shift** Quality Enhancements for the** 2-3, 4-5, and 5-4** Shifts OVERVIEW: This bulletin involves selectively erasing and reprogramming the **Transmission Control Module (TCM) with new software: '99-'01 WJ (PN 05019701AC Ver 9.3), '00 AN/DN (PN 05018454AB Ver 9.1), or '01 AN/DN (PN 56028285A1 Ver 8.4), and requires reprogramming of the Powertrain Control Module (PCM) for the 1999 and 2000 Grand Cherokees only (with calibration 99Cal20 (1999) or 00Cal17 (2000).** NOTE: THE 2001 GRAND CHEROKEE DOES NOT REQUIRE REPROGRAMMING OF THE PCM AS IT IS ALREADY AT THE CORRECT CALIBRATION LEVEL. NOTE: WHENEVER A PCM OR TCM IS REPLACED OR REPROGRAMMED, THE SOFTWARE OF THE PCM MUST BE VERIFIED AS HAVING THE LATEST REVISION LEVEL. MODELS: 2000 (AN) Dakota **2001** 2000 (DN) Durango **2001** 1999 (WJ) Grand Cherokee **2001 ** NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 4.7L ENGINE AND A 45RFE **OR 545RFE** TRANSMISSION. SYMPTOM/CONDITION: Some vehicles **may exhibit one or more of the following performance conditions **: 1. A harsh 2-3 upshift causing a powertrain clunk or shudder when accelerating. 2. **A harsh 4-5 upshift ('01 Grand Cherokee only).** 3. **A harsh 5-4 downshift ('01 Grand Cherokee only).** NOTE: THIS REVISION TO THE TCM SOFTWARE ADDRESSES THE ABOVE SHIFT QUALITY CONDITIONS FOR ALL VEHICLES AND, ADDS A FINAL GEAR RATIO TO THE **1999 AND 2000 MY** GRAND CHEROKEE TRANSMISSION ONLY. (2001 MY GRAND CHEROKEE ALREADY HAS THIS UPGRADE.) NOTE: TO MAINTAIN EMISSIONS COMPLIANCE, GRAND CHEROKEE VEHICLES THAT ARE EQUIPPED WITH A FEDERAL EMISSION SYSTEM (SALES CODE NAA) MUST HAVE THEIR PCM REPROGRAMMED. IF THE SOFTWARE LEVEL IS AT OR HIGHER THAN THOSE IN THE OVERVIEW ABOVE, OR IF THE GRAND CHEROKEE HAS A CALIFORNIA EMISSIONS SYSTEM (SALES CODE NAE), REPROGRAMMING IS NOT NECESSARY. DIAGNOSIS PROCEDURES: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRBIII(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 performing this repair. If no DTC's are present, and the above symptom has been experienced, perform the Repair Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > Customer Interest for Transmission Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts > Page 4398 Procedure. NOTE: **IF OTHER PERFORMANCE ISSUES REMAIN AFTER THE REPAIR PROCEDURE HAS BEEN PERFORMED THEY DO NOT RELATE TO THIS BULLETIN. REFER TO THE PROPER SERVICE OR DIAGNOSTIC PROCEDURES MANUAL(S) FOR FURTHER ASSISTANCE.** PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD **2093 OR HIGHER AND DRB III(R) VERSION 52.3 WILL BE IN THE DEALERSHIPS ON OCTOBER 15, 2001.)** REPAIR PROCEDURE: 1. Log onto the MDS2 (Mopar Diagnostic System). 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III(R), MDS2, AND VEHICLE ESTABLISH COMMUNICATION. 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. 3. Push the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) 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. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. 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, 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 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > Customer Interest for Transmission Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts > Page 4399 7. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 8. 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts Transmission Control Module: All Technical Service Bulletins A/T - 45RFE/545RFE Harsh Upshifts/Downshifts NUMBER: 18-025-01 GROUP: Vehicle Performance DATE: October 15, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-09-00, DATED SEPTEMBER 15, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. **ASTERISKS** HAVE BEEN USED TO HIGHLIGHT CHANGES. THIS BULLETIN ADDS A MODEL YEAR AND REQUIRES A REPROGRAMMING OF THE 1999 AND 2000 GRAND CHEROKEE POWERTRAIN CONTROL MODULE (PCM). SUBJECT: 45RFE **and 545RFE Shift** Quality Enhancements for the** 2-3, 4-5, and 5-4** Shifts OVERVIEW: This bulletin involves selectively erasing and reprogramming the **Transmission Control Module (TCM) with new software: '99-'01 WJ (PN 05019701AC Ver 9.3), '00 AN/DN (PN 05018454AB Ver 9.1), or '01 AN/DN (PN 56028285A1 Ver 8.4), and requires reprogramming of the Powertrain Control Module (PCM) for the 1999 and 2000 Grand Cherokees only (with calibration 99Cal20 (1999) or 00Cal17 (2000).** NOTE: THE 2001 GRAND CHEROKEE DOES NOT REQUIRE REPROGRAMMING OF THE PCM AS IT IS ALREADY AT THE CORRECT CALIBRATION LEVEL. NOTE: WHENEVER A PCM OR TCM IS REPLACED OR REPROGRAMMED, THE SOFTWARE OF THE PCM MUST BE VERIFIED AS HAVING THE LATEST REVISION LEVEL. MODELS: 2000 (AN) Dakota **2001** 2000 (DN) Durango **2001** 1999 (WJ) Grand Cherokee **2001 ** NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 4.7L ENGINE AND A 45RFE **OR 545RFE** TRANSMISSION. SYMPTOM/CONDITION: Some vehicles **may exhibit one or more of the following performance conditions **: 1. A harsh 2-3 upshift causing a powertrain clunk or shudder when accelerating. 2. **A harsh 4-5 upshift ('01 Grand Cherokee only).** 3. **A harsh 5-4 downshift ('01 Grand Cherokee only).** NOTE: THIS REVISION TO THE TCM SOFTWARE ADDRESSES THE ABOVE SHIFT QUALITY CONDITIONS FOR ALL VEHICLES AND, ADDS A FINAL GEAR RATIO TO THE **1999 AND 2000 MY** GRAND CHEROKEE TRANSMISSION ONLY. (2001 MY GRAND CHEROKEE ALREADY HAS THIS UPGRADE.) NOTE: TO MAINTAIN EMISSIONS COMPLIANCE, GRAND CHEROKEE VEHICLES THAT ARE EQUIPPED WITH A FEDERAL EMISSION SYSTEM (SALES CODE NAA) MUST HAVE THEIR PCM REPROGRAMMED. IF THE SOFTWARE LEVEL IS AT OR HIGHER THAN THOSE IN THE OVERVIEW ABOVE, OR IF THE GRAND CHEROKEE HAS A CALIFORNIA EMISSIONS SYSTEM (SALES CODE NAE), REPROGRAMMING IS NOT NECESSARY. DIAGNOSIS PROCEDURES: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRBIII(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 performing this repair. If no DTC's are present, and the above symptom has been experienced, perform the Repair Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts > Page 4405 Procedure. NOTE: **IF OTHER PERFORMANCE ISSUES REMAIN AFTER THE REPAIR PROCEDURE HAS BEEN PERFORMED THEY DO NOT RELATE TO THIS BULLETIN. REFER TO THE PROPER SERVICE OR DIAGNOSTIC PROCEDURES MANUAL(S) FOR FURTHER ASSISTANCE.** PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD **2093 OR HIGHER AND DRB III(R) VERSION 52.3 WILL BE IN THE DEALERSHIPS ON OCTOBER 15, 2001.)** REPAIR PROCEDURE: 1. Log onto the MDS2 (Mopar Diagnostic System). 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III(R), MDS2, AND VEHICLE ESTABLISH COMMUNICATION. 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. 3. Push the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) 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. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. 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, 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 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control Module: > 18-025-01 > Oct > 01 > A/T - 45RFE/545RFE Harsh Upshifts/Downshifts > Page 4406 7. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 8. 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > Page 4407 Transmission Control Module: Locations Fig. 13 Transmission Control Module Location The Transmission Control Module (TCM) is located in the engine compartment on the right (passenger) side and is mounted to the radiator core support. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions Transmission Control Module: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4410 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4411 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4412 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4413 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4414 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4415 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4416 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4417 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4418 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4419 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4420 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4421 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4422 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4423 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4424 Transmission Control Module: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4425 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4426 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4427 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4428 Transmission Control Module: Connector Views Transmission Control Module Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4429 Transmission Control Module Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Diagram Information and Instructions > Page 4430 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 4431 Transmission Control Module: Description and Operation Fig. 13 Transmission Control Module Location The Transmission Control Module (TCM) is located in the engine compartment on the right (passenger) side and is mounted to the radiator core support (Fig. 13). The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hardwired to, and used specifically by the TCM. Indirect inputs originate from other components/modules, and are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - DRB Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 4432 - Transmission Temperature (to PCM) - PRNDL Position (to BCM) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with DRB scan tool) NOTE: If the TCM has been replaced, the "Quick Learn Procedure" must be performed. (Refer to ELECTRONIC CONTROL MODULES/ TRANSMISSION CONTROL MODULE - STANDARD PROCEDURE) Battery Feed A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain adaptive learn values in the TCM's RAM (Random Access Memory). When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. Clutch Volume Indexes (CVI) An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. Fig. 14 Example Of CVI Calculation By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur (Fig. 14). Gear ratios can be determined by using the DRB Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 4433 The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Clutch Volumes Certain mechanical problems within the input clutch assembly (broken return springs, out of position snap rings, excessive clutch pack clearance, improper assembly, etc.) can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following chart identifies the appropriate clutch volumes and when they are monitored/updated: Shift Schedules As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 4434 Driving Conditions As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Diagrams > Page 4435 Transmission Control Module: Service and Repair STANDARD PROCEDURES The quick learn procedure requires the use of the DRB scan tool. This program allows the electronic transmission system to recalibrate itself. This will provide the proper transmission operation. The quick learn procedure should be performed if any of the following procedures are performed: Transmission Assembly Replacement - Transmission Control Module Replacement - Solenoid Pack Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees. - The shift lever position must stay in PARK until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the DRB III indicates the procedure is complete - The calculated oil temperature must be above 60 ° and below 200 ° Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Transmission Control System Relay: Locations Power Distribution Center Transmission Control Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 4439 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 4440 Transmission Control System Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 4441 Transmission Control Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 4442 Transmission Control System Relay: Description and Operation DESCRIPTION The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. OPERATION When the relay is "off," no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Recalls for Control Module: > NHTSA01V077000 > Mar > 01 > Recall 01V077000: Transfer Case Control Module Problem Control Module: Recalls Recall 01V077000: Transfer Case Control Module Problem Vehicle Description: Light duty trucks and sport utility vehicles equipped with 4-wheel drive. The electric shift transfer case may not fully engage into gear when the operator moves the transfer case selector switch. This could cause the transfer case to end up in the neutral position unexpectedly and allow the vehicle to roll away if the parking brake is not applied. Dealers will reprogram the transfer case control module. Owner notification began April 9, 2001. 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 DaimlerChrysler at 1-800-853-1403. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > NHTSA01V077000 > Mar > 01 > Recall 01V077000: Transfer Case Control Module Problem Control Module: All Technical Service Bulletins Recall 01V077000: Transfer Case Control Module Problem Vehicle Description: Light duty trucks and sport utility vehicles equipped with 4-wheel drive. The electric shift transfer case may not fully engage into gear when the operator moves the transfer case selector switch. This could cause the transfer case to end up in the neutral position unexpectedly and allow the vehicle to roll away if the parking brake is not applied. Dealers will reprogram the transfer case control module. Owner notification began April 9, 2001. 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 DaimlerChrysler at 1-800-853-1403. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Service and Repair Fluid Pressure Sensor/Switch: Service and Repair LINE PRESSURE (LP) SENSOR REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pressure sensor (Fig. 81). 4. Remove the bolt holding the line pressure sensor to the transmission case. 5. Remove the line pressure sensor from the transmission case. INSTALLATION 1. Install the line pressure sensor into the transmission case. 2. Install the bolt to hold the line pressure sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 in. lbs.). 3. Install the wiring connector onto the line pressure sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 4465 Overdrive Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 4466 Overdrive Switch: Description and Operation DESCRIPTION The overdrive OFF (control) switch is located in the shift lever arm (Fig. 95). The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function. OPERATION At key-on, overdrive operation is allowed. Pressing the switch once causes the overdrive OFF mode to be entered and the overdrive OFF switch lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the overdrive lamp to be turned off. The overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the control switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4 upshift. The control switch indicator light illuminates only when the overdrive switch is turned to the OFF position, or when illuminated by the transmission control module. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 4467 Overdrive Switch: Service and Repair REMOVAL 1. Using a plastic trim tool, remove the overdrive off switch retainer from the shift lever (Fig. 96). 2. Pull the switch outwards to release it from the connector in the lever (Fig. 97) INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector out of the lever just enough to grasp it. CAUTION: Be careful not to bend the pins on the overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 4468 2. Install the overdrive off switch into the connector (Fig. 98) 3. Push the overdrive off switch and wiring into the shift lever. 4. Install the overdrive off switch retainer onto the shift lever. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Transmission Position Switch/Sensor: Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 4475 Transmission Position Switch/Sensor: Description and Operation DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has six switch contacts that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. - Supply ground to the TCM for backup lamp control in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Specifications > 42RE (A-500) 4 Speed Transmission Speed Sensor: Specifications Sensor, trans speed 20 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Specifications > 42RE (A-500) 4 Speed > Page 4480 Transmission Speed Sensor: Specifications Bolt, input speed sensor 105 in.lb Bolt, output speed sensor 105 in.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Specifications > 42RE (A-500) 4 Speed > Page 4481 Transmission Speed Sensor: Specifications Sensor, trans speed 20 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Specifications > Page 4482 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Diagrams > Input Speed Sensor Input Speed Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Diagrams > Input Speed Sensor > Page 4485 Output Speed Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Input Speed Sensor Transmission Speed Sensor: Description and Operation Input Speed Sensor DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Input Speed Sensor > Page 4488 Transmission Speed Sensor: Description and Operation Output Speed Sensor OUTPUT SPEED SENSOR DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Service and Repair > Input Speed Sensor Transmission Speed Sensor: Service and Repair Input Speed Sensor REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (Fig. 80). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor from the transmission case. INSTALLATION 1. Install the input speed sensor into the transmission case. 2. Install the bolt to hold the input speed sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the input speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 > Service and Repair > Input Speed Sensor > Page 4491 Transmission Speed Sensor: Service and Repair Output Speed Sensor OUTPUT SPEED SENSOR REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor (Fig. 94). 4. Remove the bolt holding the output speed sensor to the transmission case. 5. Remove the output speed sensor from the transmission case. INSTALLATION 1. Install the output speed sensor into the transmission case. 2. Install the bolt to hold the output speed sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the output speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 4495 Transmission Temperature Sensor/Switch: Description and Operation DESCRIPTION The transmission temperature sensor is a thermistor that is integral to the Transmission Range Sensor (TRS). OPERATION The transmission temperature sensor is used by the TCM to sense the temperature of the fluid in the sump. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. Calculated Temperature A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Overdrive Switch, M/T > Component Information > Diagrams Overdrive Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Locations ABS Light: Locations The ABS indicator is located in the Information Center area of the instrument cluster, to the left of center. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Locations > Page 4505 ABS Light: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Anti-lock Brake .................................................................................................................................... .............................................................. PC194 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Locations > Page 4506 ABS Light: Description and Operation An Antilock Brake System (ABS) indicator is standard equipment on all instrument clusters. This indicator serves both the standard equipment Rear Wheel Anti-Lock (RWAL) and optional equipment 4-Wheel Anti-Lock (4WAL) brake systems. The ABS indicator is located in the Information Center area of the instrument cluster, to the left of center. The ABS indicator consists of a stencilled cutout of the International Control and Display Symbol icon for "Failure of Anti-lock Braking System" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber lens behind the cutout in the opaque layer of the overlay causes the icon to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by a Light Emitting Diode (LED) soldered onto the instrument cluster electronic circuit board. The ABS indicator is serviced as a unit with the instrument cluster. The ABS indicator gives an indication to the vehicle operator when the ABS system is faulty or inoperative. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Controller Antilock Brake (CAB) over the Programmable Communications Interface (PCI) data bus. The ABS indicator Light Emitting Diode (LED) receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions; therefore, the LED will always be OFF when the ignition switch is in any position except ON or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the ABS indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the ABS indicator is illuminated by the cluster for about two seconds as a bulb test. - ABS Lamp-ON Message - Each time the cluster receives a lamp-ON message from the CAB, the ABS indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the CAB, or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no lamp-ON or lamp-OFF messages from the CAB for six consecutive seconds, the ABS indicator is illuminated. The indicator remains illuminated until the cluster receives a valid message from the CAB, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the instrument cluster is put through the actuator test, the ABS indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. - ABS Diagnostic Test - The ABS indicator is blinked ON and OFF by lamp-ON and lamp-OFF messages from the CAB during the performance of the ABS diagnostic tests. The CAB continually monitors the ABS circuits and sensors to decide whether the system is in good operating condition. The CAB then sends the proper lamp-ON or lamp-OFF messages to the instrument cluster. If the CAB sends a lamp-ON message after the bulb test, it indicates that the CAB has detected a system malfunction and/or that the ABS system has become inoperative. The CAB will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the ABS indicator fails to light due to an open or short in the cluster ABS indicator circuit, the cluster sends a message notifying the CAB of the condition, and the CAB will store a DTC. For proper diagnosis of the antilock brake system, the CAB, the PCI data bus, or the message inputs to the instrument cluster that control the ABS indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump > Component Information > Diagrams Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Controller Antilock Brake: > 08-035-00 > Nov > 00 > Brakes - Vehicle Surge While Speed Control is Engaged Controller Antilock Brake: Customer Interest Brakes - Vehicle Surge While Speed Control is Engaged NUMBER: 08-035-00 GROUP: Electrical DATE: Nov. 10, 2000 SUBJECT: Vehicle Surge While Speed Control Is Engaged OVERVIEW: This bulletin involves installing a new antilock brake control module. MODELS: 2001 (AN) Dakota 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH SPEED CONTROL (SALES CODE NHM) AND FOUR WHEEL ANTILOCK BRAKES (SALES CODE BGK) BUILT ON OR BEFORE THE ILLUSTRATED DATES: SYMPTOM/CONDITION: The vehicle surges while the speed control is engaged at 74 - 76 km/h (46 - 47 mph) and/or at 109 - 111 km/h (68 - 69 mph). DIAGNOSIS/REPAIR PROCEDURES: Road test the vehicle in a location where vehicle speeds of 74 - 76 km/h (46-47 mph) and/or 109 111 km/h (68 - 69 mph) can be maintained safely. Set the speed control at 74 - 76 km/h (46 - 47 mph) or at 109 - 111 km/h (68 - 69 mph). If the vehicle surges, disengage the speed control. If the vehicle still surges, further diagnosis is required. If the vehicle surges only while the speed control is engaged, perform the Repair Procedure. NOTE: DUE TO THE NATURE OF THIS CONDITION, IT MAY BE DIFFICULT TO DUPLICATE THE SYMPTOM. IF THE CUSTOMER INDICATES THAT THE VEHICLE SURGES AT 74 - 76 KM/H (46 - 47 MPH) AND/OR AT 109 - 111 KM/H (68 - 69 MPH) ONLY WHEN THE SPEED CONTROL IS ENGAGED, PERFORM THE REPAIR PROCEDURE. PARTS REQUIRED: NOTE: ANTILOCK BRAKE CONTROLLER AVAILABILITY IS RESTRICTED. THE STAR CENTER MUST BE CONTACTED TO GET AUTHORIZATION AND TO ORDER A CONTROLLER. THE STAR CENTER'S PHONE NUMBER IS 1-800-850-STAR (7827). WHEN THE AUTOMATED ANSWERING SYSTEM REQUESTS A GROUP SELECTION, SELECT BRAKES AND THEN SELECT THE KELSEY HAYES GROUP Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Controller Antilock Brake: > 08-035-00 > Nov > 00 > Brakes - Vehicle Surge While Speed Control is Engaged > Page 4518 EQUIPMENT REQUIRED: REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. NOTE: ONCE THE ANTILOCK BRAKE CONTROL MODULE (CAB) IS REPLACED, THE REAR AXLE TYPE AND TIRE SIZE MUST BE PROGRAMED INTO THE NEW CAB. 1. Disconnect battery negative cable. 2. Push the harness connector locks to release the locks, (Fig. 1) then remove the connectors from the CAB. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Controller Antilock Brake: > 08-035-00 > Nov > 00 > Brakes - Vehicle Surge While Speed Control is Engaged > Page 4519 3. Disconnect the pump motor connector (Fig. 2). 4. Remove screws attaching CAB to the Hydraulic control Unit (HCU) (Fig. 3). 5. Remove the CAB. 6. Place the new CAB onto the HCU (see Parts Required section). NOTE: ENSURE THE CAB SEAL IS IN POSITION BEFORE INSTALLATION. 7. Install the mounting screws and tighten to 4-4.7 N.m (36-42 in. lbs.). 8. Connect the pump motor harness. 9. Connect the harnesses to the CAB and lock the connectors. 10. Connect battery. NOTE: THE NEW CAB MUST HAVE THE TIRE SIZE AND AXLE TYPE PROGRAMMED INTO THE NEW CONTROLLER IN ORDER TO HAVE THE CONTROLLER COMMUNICATE THE PROPER VEHICLE SPEED. FAILURE TO PROPERLY PROGRAM THE REPLACEMENT CAB WILL RESULT IN A BLINKING ABS INDICATOR. 11. Inspect rear tires to determine tire sizes. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Controller Antilock Brake: > 08-035-00 > Nov > 00 > Brakes - Vehicle Surge While Speed Control is Engaged > Page 4520 12. Determine which rear axle type is used on this vehicle. Refer to the following graphics to help in identifying axle types (Fig. 4) (Fig. 5). 13. Using the DRBIII(R) select: MISC in the Antilock Brake menu. Then, SET PINION FACTOR. NOTE: THE DRBIII(R) MENU SCREEN CAN ONLY PROGRAM PRODUCTION SIZE TIRES THAT WERE CERTIFIED FOR THE VEHICLE WHEN THE VEHICLE WAS MANUFACTURED. IF THE TIRES ON THE VEHICLE DO NOT MATCH TIRE SIZES AVAILABLE ON THE DRBIII(R) MENU SCREEN, THEN THE TIRE ON THE VEHICLE WAS NEVER CERTIFIED FOR USAGE. 14. Turn the ignition switch to the RUN position (engine not running). 15. With the DRBIII(R), program the correct tire size and rear axle type. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Controller Antilock Brake: > 08-035-00 > Nov > 00 > Brakes - Vehicle Surge While Speed Control is Engaged > Page 4521 16. Road test the vehicle above 48 km/h (30 mph) for at least two minutes to ensure that the antilock brake system functions as designed. If the ABS warning lamp illuminates during the road test, further diagnosis is required. Refer to the appropriate Chassis Diagnostic Manual or the service information available in the MDS2. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Controller Antilock Brake: > 08-035-00 > Nov > 00 > Brakes - Vehicle Surge While Speed Control is Engaged Controller Antilock Brake: All Technical Service Bulletins Brakes - Vehicle Surge While Speed Control is Engaged NUMBER: 08-035-00 GROUP: Electrical DATE: Nov. 10, 2000 SUBJECT: Vehicle Surge While Speed Control Is Engaged OVERVIEW: This bulletin involves installing a new antilock brake control module. MODELS: 2001 (AN) Dakota 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH SPEED CONTROL (SALES CODE NHM) AND FOUR WHEEL ANTILOCK BRAKES (SALES CODE BGK) BUILT ON OR BEFORE THE ILLUSTRATED DATES: SYMPTOM/CONDITION: The vehicle surges while the speed control is engaged at 74 - 76 km/h (46 - 47 mph) and/or at 109 - 111 km/h (68 - 69 mph). DIAGNOSIS/REPAIR PROCEDURES: Road test the vehicle in a location where vehicle speeds of 74 - 76 km/h (46-47 mph) and/or 109 111 km/h (68 - 69 mph) can be maintained safely. Set the speed control at 74 - 76 km/h (46 - 47 mph) or at 109 - 111 km/h (68 - 69 mph). If the vehicle surges, disengage the speed control. If the vehicle still surges, further diagnosis is required. If the vehicle surges only while the speed control is engaged, perform the Repair Procedure. NOTE: DUE TO THE NATURE OF THIS CONDITION, IT MAY BE DIFFICULT TO DUPLICATE THE SYMPTOM. IF THE CUSTOMER INDICATES THAT THE VEHICLE SURGES AT 74 - 76 KM/H (46 - 47 MPH) AND/OR AT 109 - 111 KM/H (68 - 69 MPH) ONLY WHEN THE SPEED CONTROL IS ENGAGED, PERFORM THE REPAIR PROCEDURE. PARTS REQUIRED: NOTE: ANTILOCK BRAKE CONTROLLER AVAILABILITY IS RESTRICTED. THE STAR CENTER MUST BE CONTACTED TO GET AUTHORIZATION AND TO ORDER A CONTROLLER. THE STAR CENTER'S PHONE NUMBER IS 1-800-850-STAR (7827). WHEN THE AUTOMATED ANSWERING SYSTEM REQUESTS A GROUP SELECTION, SELECT BRAKES AND THEN SELECT THE KELSEY HAYES GROUP Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Controller Antilock Brake: > 08-035-00 > Nov > 00 > Brakes - Vehicle Surge While Speed Control is Engaged > Page 4527 EQUIPMENT REQUIRED: REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. NOTE: ONCE THE ANTILOCK BRAKE CONTROL MODULE (CAB) IS REPLACED, THE REAR AXLE TYPE AND TIRE SIZE MUST BE PROGRAMED INTO THE NEW CAB. 1. Disconnect battery negative cable. 2. Push the harness connector locks to release the locks, (Fig. 1) then remove the connectors from the CAB. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Controller Antilock Brake: > 08-035-00 > Nov > 00 > Brakes - Vehicle Surge While Speed Control is Engaged > Page 4528 3. Disconnect the pump motor connector (Fig. 2). 4. Remove screws attaching CAB to the Hydraulic control Unit (HCU) (Fig. 3). 5. Remove the CAB. 6. Place the new CAB onto the HCU (see Parts Required section). NOTE: ENSURE THE CAB SEAL IS IN POSITION BEFORE INSTALLATION. 7. Install the mounting screws and tighten to 4-4.7 N.m (36-42 in. lbs.). 8. Connect the pump motor harness. 9. Connect the harnesses to the CAB and lock the connectors. 10. Connect battery. NOTE: THE NEW CAB MUST HAVE THE TIRE SIZE AND AXLE TYPE PROGRAMMED INTO THE NEW CONTROLLER IN ORDER TO HAVE THE CONTROLLER COMMUNICATE THE PROPER VEHICLE SPEED. FAILURE TO PROPERLY PROGRAM THE REPLACEMENT CAB WILL RESULT IN A BLINKING ABS INDICATOR. 11. Inspect rear tires to determine tire sizes. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Controller Antilock Brake: > 08-035-00 > Nov > 00 > Brakes - Vehicle Surge While Speed Control is Engaged > Page 4529 12. Determine which rear axle type is used on this vehicle. Refer to the following graphics to help in identifying axle types (Fig. 4) (Fig. 5). 13. Using the DRBIII(R) select: MISC in the Antilock Brake menu. Then, SET PINION FACTOR. NOTE: THE DRBIII(R) MENU SCREEN CAN ONLY PROGRAM PRODUCTION SIZE TIRES THAT WERE CERTIFIED FOR THE VEHICLE WHEN THE VEHICLE WAS MANUFACTURED. IF THE TIRES ON THE VEHICLE DO NOT MATCH TIRE SIZES AVAILABLE ON THE DRBIII(R) MENU SCREEN, THEN THE TIRE ON THE VEHICLE WAS NEVER CERTIFIED FOR USAGE. 14. Turn the ignition switch to the RUN position (engine not running). 15. With the DRBIII(R), program the correct tire size and rear axle type. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Controller Antilock Brake: > 08-035-00 > Nov > 00 > Brakes - Vehicle Surge While Speed Control is Engaged > Page 4530 16. Road test the vehicle above 48 km/h (30 mph) for at least two minutes to ensure that the antilock brake system functions as designed. If the ABS warning lamp illuminates during the road test, further diagnosis is required. Refer to the appropriate Chassis Diagnostic Manual or the service information available in the MDS2. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Page 4531 Controller Antilock Brake: Specifications Controller Mounting Screws 53 in.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > EBC 325 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > EBC 325 > Page 4534 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > Page 4535 Controller Antilock Brake: Diagrams Controller Antilock Brake C1 Controller Antilock Brake C2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > Page 4536 Controller Antilock Brake: Description and Operation CONTROLLER REAR WHEEL ANTILOCK BRAKES Fig. 3 RWAL Cab The Controller Antilock Brakes (CAB) is a microprocessor which handles testing, monitoring and controlling the ABS brake system operation. The CAB functions are: Perform self-test diagnostics. - Monitor the RWAL brake system for proper operation. - Control the RWAL valve solenoids. Fig. 4 CAB/HCU The CAB is mounted on the top of the hydraulic control unit. The CAB operates the ABS system and is separate from other vehicle electrical circuits. CAB voltage source is through the ignition switch in the RUN position. NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. For axle type refer to Differential and Driveline. System Self-test When the ignition switch is turned-ON the microprocessor RAM and ROM are tested. If an error occurs during the test, a DTC will be set into the RAM memory. However it is possible the DTC will not be stored in memory if the error has occurred in the RAM module were the DTC's are Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > Page 4537 stored. Also it is possible a DTC may not be stored if the error has occurred in the ROM which signals the RAM to store the DTC. The CAB contains a self check program that illuminates the ABS warning light when a system fault is detected. Faults are stored in a diagnostic program memory and are accessible with the DRB scan tool. ABS faults remain in memory until cleared, or until after the vehicle is started approximately 50 times. Stored faults are not erased if the battery is disconnected. CAB Inputs The CAB continuously monitors the speed of the differential ring gear by monitoring signals generated by the rear wheel speed sensor. The CAB determines a wheel locking tendency when it recognizes the ring gear is decelerating too rapidly. The CAB monitors the following inputs to determine when a wheel locking tendency may exists: Rear Wheel Speed Sensor - Brake Lamp Switch - Brake Warning Lamp Switch - Reset Switch - 4WD Switch (If equipped) CAB Outputs The CAB controls the following outputs for antilock braking and brake warning information: RWAL Valve - ABS Warning Lamp - Brake Warning Lamp Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > Page 4538 Controller Antilock Brake: Service and Repair REMOVAL NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. For axle type refer to Differential and Driveline. Fig. 5 Harness Connector Locks 1. Push the CAB harness connector lock to release the lock and remove the connector from the controller. Fig. 6 Pump Motor Connector 2. Remove the RWAL valve harness and the pump motor connectors from the controller. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > Page 4539 Fig. 7 RWAL Controller 3. Remove the controller mounting screws and remove the controller from the mounting bracket. INSTALLATION NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. 1. Position the controller on the bracket. 2. Install the mounting screws and tighten to 6 Nm (53 in. lbs). 3. Install the RWAL valve harness connector into the controller. 4. Install the CAB harness connector into the controller and push down on the connector lock. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Rear Wheel Antilock System Hydraulic Control Assembly - Antilock Brakes: Specifications RWAL Valve Mounting Bolt 15-20 ft.lb Brake Line Fittings 170 in.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Rear Wheel Antilock System > Page 4544 Hydraulic Control Assembly - Antilock Brakes: Specifications ABS Assembly Bracket bolts 10-12 ft.lb Mounting Nuts 102 in.lb CAB Screws 36-42 in.lb Brake Line Fittings 170 in.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > Four Wheel Antilock Brake System Hydraulic Control Assembly - Antilock Brakes: Description and Operation Four Wheel Antilock Brake System DESCRIPTION The hydraulic control unit (HCU) consists of a valve body, pump, two accumulators and a motor. The assembly is mounted on the driver side inner fender under the hood. OPERATION The pump, motor, and accumulators are combined into an assembly attached to the valve body. The accumulators store the extra fluid which had to be dumped from the brakes. This is done to prevent the wheels from locking up. The pump provides the fluid volume needed and is operated by a DC type motor. The motor is controlled by the CAB. During normal braking, the HCU solenoid valves and pump are not activated. The master cylinder and power booster operate the same as a vehicle without an ABS brake system. The valve body contains the solenoid valves. The valves modulate brake pressure during antilock braking and are controlled by the CAB. The HCU provides three channel pressure control to the front and rear brakes. One channel controls the rear wheel brakes in tandem. The two remaining channels control the front wheel brakes individually. During antilock braking, the solenoid valves are opened and closed as needed. The valves are not static. They are cycled rapidly and continuously to modulate pressure and control wheel slip and deceleration. During antilock braking, solenoid valve pressure modulation occurs in three stages, pressure decrease, pressure hold, and pressure increase. The valves are all contained in the valve body portion of the HCU. PRESSURE DECREASE The inlet valve is closed and the outlet valve is opened during the pressure decrease cycle . A pressure decrease cycle is initiated when speed sensor signals indicate high wheel slip at one or more wheels. At this point, the CAB closes the inlet to prevent the driver from further increasing the brake pressure and locking the brakes. The CAB then opens the outlet valve, which also opens the return circuit to the accumulators. Fluid pressure is allowed to bleed off (decrease) as needed to prevent wheel lock. Once the period of high wheel slip has ended, the CAB closes the outlet valve and begins a pressure increase or hold cycle as needed. PRESSURE HOLD Both solenoid valves are closed in the pressure hold cycle . Fluid apply pressure in the control channel is maintained at a constant rate. The CAB maintains the hold cycle until sensor inputs indicate a pressure change is necessary. PRESSURE INCREASE The inlet valve is open and the outlet valve is closed during the pressure increase cycle. The pressure increase cycle is used to counteract unequal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > Four Wheel Antilock Brake System > Page 4547 wheel speeds. This cycle controls re-application of fluid apply pressure due to changing road surfaces or wheel speed. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > Four Wheel Antilock Brake System > Page 4548 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Rear Wheel Antilock Brakes DESCRIPTION The valve is located on the drivers side inner fender under the hood. The valve modulates hydraulic pressure to the rear brakes during an RWAL stop. OPERATION If the CAB senses that rear wheel speed deceleration is excessive, it will energize an isolation solenoid by providing battery voltage to the solenoid. This prevents a further increase of driver induced brake pressure to the rear wheels. If this initial action is not enough to prevent rear wheel lock-up, the CAB will momentarily energize a dump solenoid (the CAB energizes the dump solenoid by providing battery voltage to the solenoid). This opens the dump valve to vent a small amount of isolated rear brake pressure to an accumulator. The action of fluid moving to the accumulator reduces the isolated brake pressure at the wheel cylinders. The dump (pressure venting) cycle is limited to very short time periods (milliseconds). The CAB will pulse the dump valve until rear wheel deceleration matches the desired slip rate programmed into the CAB. The system will switch to normal braking once wheel locking tendencies are no longer present. A predetermined maximum number of consecutive dump cycles can be performed during any RWAL stop. If excessive dump cycles occur, a DTC will be set and stored in the CAB memory. If during a RWAL stop, the driver releases the brake pedal, the reset switch contacts will open. This signal to the CAB is an indication that pressure has equalized across the RWAL valve. The CAB will then reset the dump cycle counter in anticipation of the next RWAL stop. Additionally, any fluid stored in the accumulator will force its way past the dump valve, back into the hydraulic circuit and return to the master cylinder. A fuse internal to the CAB, provides a fail-safe device which prevents unwanted control over the isolation and dump solenoids. The fuse is in series with the isolation and dump solenoids output circuits. If the internal fuse is open, the CAB cannot provide voltage to energize either solenoid and RWAL stops are prevented. If the fuse is open, the braking system will operate normally but without antilock control over rear brake pressure. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Four Wheel Antilock Brake System Hydraulic Control Assembly - Antilock Brakes: Service and Repair Four Wheel Antilock Brake System REMOVAL (1) Disconnect battery negative cable. HCU Brake Lines (2) Remove the brake lines from HCU. (3) Push the harness connector locks to release the locks, then remove the connectors from the CAB. (4) Remove the nuts which attaches the assembly to the mounting bracket. (5) Remove the assembly from the vehicle. INSTALLATION (1) Install the antilock assembly into the bracket and tighten bolts to 14 - 15 Nm (10 - 12 ft. lbs). (2) Connect the CAB harnesses. (3) Connect the brake lines to the HCU. Tighten brake line fittings to 19 Nm (170 inch lbs.). (4) Connect battery. (5) Bleed brake system. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Four Wheel Antilock Brake System > Page 4551 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Rear Wheel Antilock Brake System REMOVAL (1) Remove RWAL valve harness connector from the RWAL controller. (2) Remove the brake lines from the valve. RWAL Valve (3) Remove the valve mounting bolt and remove the valve from the bracket. INSTALLATION (1) Position the valve on the bracket and install the mounting bolt. Tighten the mounting bolt to 20 27 Nm (15 - 20 ft. lbs.). (2) Install the brake lines and tighten to 19 Nm (170 inch lbs.). (3) Install the RWAL valve harness connector into the RWAL controller. (4) Bleed base brake system. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Four Wheel Antilock Brake System Wheel Speed Sensor: Specifications Wheel Speed Sensors Front Sensor Bolt 190 in.lb Rear Sensor Bolt 200 in.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Four Wheel Antilock Brake System > Page 4556 Wheel Speed Sensor: Specifications Wheel Speed Sensor Mounting Bolt 200 in.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations Wheel Speed Sensor: Component Locations Front Wheel Speed Sensor/Tone Wheels Rear Wheel Speed Sensors/Tone Wheels Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4559 Wheel Speed Sensor: Connector Locations Left Front Wheel Speed Sensor Connector Right Front Wheel Speed Sensor Connector Rear Wheel Speed Sensor Connector Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 4560 Wheel Speed Sensor: Diagrams Left Front Wheel Speed Sensor (Sensor Side) Left Front Wheel Speed Sensor Rear Wheel Speed Sensor Right Front Wheel Speed Sensor (Sensor Side) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 4561 Right Front Wheel Speed Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Rear Wheel Antilock Brake System Wheel Speed Sensor: Description and Operation Rear Wheel Antilock Brake System DESCRIPTION The rear Wheel Speed Sensor (WSS) is mounted in the rear differential housing. The exciter ring is press fitted onto the differential carrier next to the final drive ring gear. For replacement procedure of the exciter ring. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Rear Wheel Antilock Brake System > Page 4564 Wheel Speed Sensor: Description and Operation Wheel Speed Sensor OPERATION The WSS consists of a magnet surrounded by windings from a single strand of wire. The sensor sends a small AC signal to the CAB. This signal is generated by magnetic induction. The magnetic induction is created when a toothed sensor ring (exciter ring or tone wheel) passes the stationary magnetic WSS. When the ring gear is rotated, the exciter ring passes the tip of the WSS. As the exciter ring tooth approaches the tip of the WSS, the magnetic lines of force expand, causing the magnetic field to cut across the sensor's windings. This, in turn causes current to flow through the WSS circuit in one direction. When the exciter ring tooth moves away from the sensor tip, the magnetic lines of force collapse cutting the winding in the opposite direction. This causes the current to flow in the opposite direction. Every time a tooth of the exciter ring passes the tip of the WSS, an AC signal is generated. Each AC signal (positive to negative signal or sinewave) is interpreted by the CAB. It then compares the frequency of the sinewave to a time value to calculate vehicle speed. The CAB continues to monitor the frequency to determine a deceleration rate that would indicate a possible wheel-locking tendency. The signal strength of any magnetic induction sensor is directly affected by: - Magnetic field strength; the stronger the magnetic field, the stronger the signal - Number of windings in the sensor; more windings provide a stronger signal - Exciter ring speed; the faster the exciter ring/tone wheel rotates, the stronger the signal will be - Distance between the exciter ring teeth and WSS; the closer the WSS is to the exciter ring/tone wheel, the stronger the signal will be The rear WSS is not adjustable. A clearance specification has been established for manufacturing tolerances. If the clearance is not within these specifications, then either the WSS or other components may be damaged. The clearance between the WSS and the exciter ring is 0.005 0.050 inch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Rear Wheel Antilock Brake System > Page 4565 The assembly plant performs a "Rolls Test" on every vehicle that leaves the assembly plant. One of the test performed is a test of the WSS. To properly test the sensor, the assembly plant connects test equipment to the Data Link Connector (DLC). This connector is located to the right of the steering column and attached to the lower portion of the instrument panel. The rolls test terminal is spliced to the WSS circuit. The vehicle is then driven on a set of rollers and the WSS output is monitored for proper operation. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 REMOVAL - 2WD (1) Raise and support vehicle. (2) Remove bolt attaching sensor to the steering knuckle. (3) Remove clamps securing sensor wire to control arm and inner fender panel. (4) In engine compartment, disconnect sensor wire from harness and remove sensor. INSTALLATION - 2WD (1) Position sensor in the knuckle and install sensor attaching bolts. Tighten bolts to 21 Nm (190 inch lbs.). (2) Secure sensor wire retaining clamps to control arm and fender panel. (3) In engine compartment, connect sensor wire to harness connector. Make sure wire is routed away from hot or rotating underhood components. (4) Turn steering wheel back and forth to verify that wire is clear of steering and suspension components. (5) Remove supports and lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 4568 Wheel Speed Sensor: Service and Repair Rear REAR WHEEL SPEED SENSOR REMOVAL (1) Raise vehicle on hoist. (2) Remove brake line mounting nut and remove the brake line from the sensor stud. (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 O-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 (200 inch lbs.). (6) Install the brake line on the sensor stud and install the nut. (7) Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding Brake Bleeding: Service and Repair Master Cylinder Bleeding STANDARD PROCEDURE - MASTER CYLINDER BLEEDING A new master cylinder should be bled before installation on the vehicle. Required bleeding tools include bleed tubes and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from brake line. (1) Mount master cylinder in vise. Master Cylinder Bleeding - Typical (2) Attach bleed tubes to cylinder outlet ports. Then position each tube end into the reservoir. (3) Fill reservoir with fresh brake fluid. (4) Press cylinder pistons inward with wood dowel. Then release pistons and allow them to return under spring pressure. Continue bleeding operations until air bubbles are no longer visible in fluid Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 4573 Brake Bleeding: Service and Repair Standard Procedure - Manual Bleeding STANDARD PROCEDURE - MANUAL BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. 1. Remove reservoir filler caps and fill reservoir. 2. If calipers, or wheel cylinders were overhauled, open all caliper and wheel cylinder bleed screws. Then close each bleed screw as fluid starts to drip from it. Top off master cylinder reservoir once more before proceeding. 3. Attach one end of bleed hose to bleed screw and insert opposite end in glass container partially filled with brake fluid. Be sure end of bleed hose is immersed in fluid. 4. Open up bleeder, then have a helper press down the brake pedal. Once the pedal is down close the bleeder. Repeat bleeding until fluid stream is clear and free of bubbles. Then move to the next wheel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 4574 Brake Bleeding: Service and Repair Standard Procedure - Pressure Bleeding STANDARD PROCEDURE - PRESSURE BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Generally, a tank pressure of 15 - 20 psi is sufficient for bleeding. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding. Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system. Use adapter provided with the equipment or Adapter 6921. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Description and Operation Brake Pedal Assy: Description and Operation DESCRIPTION A suspended-type brake pedal is used. The pedal is attached to the pedal support bracket with a pivot pin and bushings. The booster push rod is attached to the pedal with a clip. The pedal, bushings, pivot pin and support bracket are all serviceable components. OPERATION The brake pedal is attached to the booster push rod. When the pedal is depressed, the primary booster push rod is depressed which move the booster secondary rod. The booster secondary rod depress the master cylinder piston. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Description and Operation > Page 4578 Brake Pedal Assy: Service and Repair REMOVAL (1) Remove the stop lamp switch (2) Remove the clip securing the booster push rod to the brake pedal. (3) Remove the pedal pivot pin C-clip and slide pin out of support bracket and pedal. (4) Remove the pedal and bushings. INSTALLATION (1) Replace the bushings if worn or damaged. (2) Lubricate the pedal bushings and pivot pin with Mopar multi mileage grease, Lubriplate, or a silicone grease. (3) Install the bushings in pedal and position pedal in support. (4) Insert the pivot pin through the support and the pedal bushings and install the C-clip. (5) Install the booster push rod on the brake pedal and install the push rod retainer clip. (6) Install the stop lamp switch. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Locations Brake Warning Indicator: Locations The brake indicator is located in the Information Center area of the instrument cluster; to the right of center. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Locations > Page 4582 Brake Warning Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Brake Warning ..................................................................................................................................... .............................................................. PC194 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Locations > Page 4583 Brake Warning Indicator: Description and Operation BRAKE/PARK BRAKE INDICATOR A brake indicator is standard equipment on all instrument clusters. The brake indicator is located in the Information Center area of the instrument cluster; to the right of center. The brake indicator consists of a stenciled cutout of the word "BRAKE" and the International Control and Display Symbol icons for "Brake Failure" and "Parking Brake" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red lens behind the cutout in the opaque layer of the overlay causes the "BRAKE" text and the two icons to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by a Light Emitting Diode (LED) soldered onto the instrument cluster electronic circuit board. The brake indicator is serviced as a unit with the instrument cluster. The brake indicator gives an indication to the vehicle operator when the parking brake is applied, or when there are certain brake hydraulic system malfunctions. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming, and electronic messages received by the cluster from the Central Timer Module (CTM) and the Controller Antilock Brake (CAB) over the Programmable Communications Interface (PCI) data bus. The brake indicator Light Emitting Diode (LED) receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions; therefore, the LED will always be OFF when the ignition switch is in any position except ON or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the brake indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the brake indicator is illuminated by the instrument cluster for about four seconds as a bulb test. - Brake Lamp-On Message - Each time the cluster receives a lamp-on message from the CTM or the CAB, the brake indicator will be illuminated. If the park brake is applied or not fully released, or if the pressures in the two halves of the split brake hydraulic system are not equal with the ignition switch in the ON position, the brake indicator is illuminated solid. The brake indicator will blink ON and OFF repeatedly when the park brake is applied or not fully released and the ignition switch is in the ON position if the automatic transmission is not in Park or Neutral. The indicator remains illuminated until the cluster receives lamp-off messages from both the CTM and the CAB, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the instrument cluster is put through the actuator test, the brake indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The park brake switch on the park brake pedal mechanism provides a hard wired ground input to the CTM circuitry through the park brake switch sense circuit whenever the park brake is applied or not fully released. The CTM then sends the proper lamp-ON or lamp-OFF messages to the instrument cluster. The brake pressure switch on the brake combination valve provides a hard wired ground input to the CAB circuitry through the brake pressure switch sense circuit whenever the pressures in the two halves of the split brake hydraulic system are unequal. The CAB then sends the proper lamp-ON or lamp-OFF messages to the instrument cluster. If the CAB sends a lamp-ON message after the bulb test, it indicates that the CAB has detected a brake hydraulic system malfunction and/or that the ABS system has become inoperative. The CAB will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. The park brake switch input to the CTM and the brake pressure switch input to the CAB can be diagnosed using conventional diagnostic tools and methods. For proper diagnosis of the antilock brake system, the CTM, the CAB, the PCI data bus, or the message inputs to the instrument cluster that control the brake indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Disc Brake Caliper Type Sliding Bore 2.75 in Mounting Pins 22 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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) Clean master cylinder reservoir and filler caps. (2) Remove reservoir filler cap and drain approximately 1/4 of fluid from reservoir. Use clean suction gun or similar device to drain fluid. (3) Raise and support vehicle. (4) Remove front wheel and tire assemblies. (5) Bottom caliper pistons in bores with large C-clamp. Position clamp frame on rear of caliper and clamp screw on outboard brake shoe. (6) Disconnect brake hose at caliper. Discard hose fitting washers if worn, or damaged. (7) With a screw driver pry up on the caliper spring and pull the spring out of the caliper holes. (8) Remove caliper and brake shoes from caliper. INSTALLATION (1) Install the brake shoes in the caliper. (2) Install the caliper and shoes over rotor and into ledges in steering knuckle. Be sure ends of brake shoes are properly seated on slide surfaces of ledges. (3) Install and tighten the caliper slide pins to 30 Nm (22 ft. lbs.). Start the slide pins by hand before tightening. Do not cross thread the pins. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4590 (4) Install the caliper spring into one caliper hole and under the adapter. Pull down on the opposite end of the spring and hold the end under the adapter. With a screw driver pry up on the spring to seat the spring into the other caliper hole. NOTE: Verify the spring is seated properly into the caliper holes. (5) Install the brake hose to the caliper with new seal washers and tighten fitting bolt to 24 Nm (18 ft. lbs.). CAUTION: Verify brake hose is not twisted or kinked before tightening fitting bolt. (6) Bleed the base brake system. (7) Install the wheel and tire assemblies. (8) Remove the supports and lower the vehicle. (9) Pump the brake pedal to seat brake shoes. (10) Fill the brake fluid reservoir. (11) Verify a firm pedal before moving the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4591 Brake Caliper: Service and Repair Disassembly and Assembly DISASSEMBLY (1) Drain old brake fluid out of caliper into drain pan. Piston Dust Boot (2) Remove piston dust boot. Use screwdriver to push boot out of groove. (3) Pad outboard shoe side of caliper interior with a minimum 1 inch thickness of shop towels. Towels will prevent piston damage when piston comes out of the caliper bore. (4) Remove caliper piston with short bursts of compressed air. Apply air pressure through fluid inlet port of caliper. CAUTION: Do not blow the piston out of the bore with sustained air pressure. This could result in a cracked piston. Use only enough air Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4592 pressure to ease the piston out. WARNING: NEVER ATTEMPT TO CATCH THE PISTON AS IT LEAVES THE BORE. THIS MAY RESULT IN PERSONAL INJURY. Caliper Piston Seal (5) Remove caliper piston seal with wood pencil or plastic tool. Do not use metal tools as they will scratch piston bore. (6) Remove caliper slide pin bushings and boots. (7) Remove caliper bleed screw and cap. ASSEMBLY (1) Lubricate slide pin boots and bushings with GE, or Dow silicone grease. Then install the boots and bushings in caliper. (2) Coat caliper piston bore, piston and new piston seal with clean brake fluid. Fig 19 Installing Caliper Piston Seal (3) Install new piston seal in caliper bore. Press seal into groove with finger. Lubricate seal and caliper bore with additional, fresh brake fluid after seal installation. (4) Apply light coat of GE 661, Dow 111 or similar silicone grease to edge and groove of piston and dust seal. Grease acts as corrosion protection for these areas. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4593 Sliding Boot Onto Piston (5) Slide new seal boot over piston until boot lip seats in piston groove. Snapping Boot Folds Into Place (6) Push retainer part of boot forward until folds in boot snap into place. Installing Caliper Piston And Boot (7) Start caliper piston in bore with a twisting motion. When piston is started in seal, push piston only part way into bore. Maintain uniform pressure on piston to avoid cocking it in bore. (8) Press caliper piston to bottom of bore. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4594 Seating Piston Dust Boot (9) Seat piston dust boot with Installer 8248 and Handle C-4171. Caliper Bleed Screw & Cap Installation (10) Install caliper bleed screw and bleed screw cap if removed. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4595 Brake Caliper: Service and Repair Cleaning and Inspection CLEANING Clean the caliper components with clean brake fluid or brake clean only. Wipe the caliper and piston dry with lint free towels or use low pressure compressed air. CAUTION: Do not use gasoline, kerosene, paint thinner, or similar solvents. These products may leave a residue that could damage the piston and seal. INSPECTION The piston is made from a phenolic resin (plastic material) and should be smooth and clean. The piston must be replaced if cracked or scored. Do not attempt to restore a scored piston surface by sanding or polishing. CAUTION: If the caliper piston is replaced, install the same type of piston in the caliper. Never inter-change phenolic resin and steel caliper pistons. The pistons, seals, seal grooves, caliper bore and piston tolerances are different. Fig 14 Honing Piston Bore The bore can be lightly polished with a brake hone to remove very minor surface imperfections. The caliper should be replaced if the bore is severely corroded, rusted, scored, or if polishing would increase bore diameter more than 0.025 mm (0.001 inch). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications Riveted brake pads should be replaced when worn to within 0.78 mm (1/32 inch) of the rivet heads. Bonded linings should be replaced when worn to a thickness of 1.6 mm (1/16 inch). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 4599 Brake Pad: Service and Repair BRAKE PADS/SHOES REMOVAL - FRONT DISC BRAKE SHOES (1) Clean master cylinder reservoir and filler caps. (2) Remove reservoir filler cap and drain approximately 1/4 of fluid from reservoir. Use clean suction gun or similar device to drain fluid. (3) Raise and support the vehicle. (4) Remove the front wheel and tire assemblies. (5) Bottom the caliper pistons in bores with large C-clamp. Position the clamp frame on rear of caliper and clamp screw on outboard brake shoe. (6) With a screw driver pry up on the caliper spring and pull the spring out of the caliper holes. (7) Remove caliper slide pins. (8) Remove caliper and brake shoes,. (9) Remove outboard brake shoe. Pry one end of shoe retainer spring away from caliper. Then tilt shoe upward and rotate it out of caliper. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 4600 Inboard Brake Shoe (10) Remove inboard shoe by tilting shoe outward until retainer spring is clear of caliper piston. (11) Support caliper with wire from suspension component . Do not allow brake hose to support caliper weight. INSTALLATION - FRONT DISC BRAKE SHOES (1) Clean the slide surfaces of adapter ledges with a wire brush. Then lubricate surfaces with a thin coat of high temperature grease. (2) Install the new slide pin bushings if necessary. (3) Install the inboard shoe. Be sure the retainer spring is firmly seated in the caliper piston. (4) Insert the outboard brake shoe in the caliper. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 4601 (5) Insure the outboard shoe retainer spring is seated in the caliper. (6) Install the caliper and the brake shoes over rotor and into the adapter. (7) Install and tighten the caliper slide pins to 30 Nm (22 ft. lbs.). Start the slide pins by hand before tightening. Do not cross thread the pins. (8) Install the caliper spring into one caliper hole and under the adapter. Pull down on the opposite end of the springand hold the end under the adapter. With a screw driver pry up on the spring to seat the spring into the other caliper hole. NOTE: Verify the spring is seated properly into the caliper holes. (9) Install the wheel and tire assembly. (10) Remove the support and the lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 4602 (11) Pump the brake pedal to seat the brake shoes. (12) Fill the brake fluid reservoir. (13) Verify a firm brake pedal before moving the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications Brake Rotor/Disc: Specifications Rotor Specifications Rotor Specifications DISC BRAKE ROTOR TYPE Ventilated ROTOR DIAMETER 287 mm (11.3 in.) STANDARD ROTOR THICKNESS 24 mm (0.945 in.) MINIMUM ROTOR THICKNESS 22.6 mm (0.889 in.) ROTOR THICKNESS VARIATION (MAX) 0.013 mm (0.0005 in.) ROTOR RUNOUT (MAX) 0.102 mm (0.004 in.) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4606 Brake Rotor/Disc: Testing and Inspection DIAGNOSIS AND TESTING - DISC BRAKE ROTOR The rotor braking surfaces should not be refinished unless necessary. Light surface rust and scale can be removed with a lathe equipped with dual sanding discs. The rotor surfaces can be restored by machining in a disc brake lathe if surface scoring and wear are light. Replace the rotor under the following conditions: severely scored - tapered - hard spots - cracked - below minimum thickness ROTOR MINIMUM THICKNESS Measure rotor thickness at the center of the brake shoe contact surface. Replace the rotor if worn below minimum thickness, or if machining would reduce thickness below the allowable minimum. Rotor minimum thickness is usually specified on the rotor hub. The specification is either stamped or cast into the hub surface. ROTOR RUNOUT Check rotor lateral runout with dial indicator C-3339. Excessive lateral runout will cause brake pedal pulsation and rapid, uneven wear of the brake shoes. Position the dial indicator plunger approximately 25.4 mm (1 inch) inward from the rotor edge. Maximum allowable rotor runout is 0.102 mm(0.004 inch). ROTOR THICKNESS VARIATION Variations in rotor thickness will cause pedal pulsation, noise and shudder. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4607 Measure rotor thickness at 6 to 12 points around the rotor face. Position the micrometer approximately 25.4 mm (1 inch) frown the rotor outer circumference for each measurement. Thickness should not vary by more than 0.013 mm (0.0005 inch) from point-to-point on the rotor. Machine or replace the rotor if necessary. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor - Removal and Installation Brake Rotor/Disc: Service and Repair Brake Rotor - Removal and Installation REMOVAL (1) Raise and support the vehicle. (2) Remove the wheel and tire assembly. (3) Remove the brake caliper. (4) Remove the retainers on the wheel studs and remove the rotor. INSTALLATION (1) Install the rotor hub and install the retainers. (2) Install the brake caliper. (3) Install the wheel and tire assembly. (4) Remove the support and lower the vehicle. (5) Depress the brake pedal several time to seat the brake shoes. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor - Removal and Installation > Page 4610 Brake Rotor/Disc: Service and Repair Brake Rotor Machining STANDARD PROCEDURE - DISC ROTOR MACHINING The disc brake rotor can be machined if scored or worn. The lathe must machine both sides of the rotor simultaneously with dual cutter heads. The rotor mounting surface must be clean before placing on the lathe. Equipment capable of machining only one side at a time may produce a tapered rotor. NOTE: A hub mounted on-vehicle lathe is recommended. This type of lathe trues the rotor to the vehicles hub/bearing. CAUTION: Brake rotors that do not meet minimum thickness specifications before or after machining must be replaced. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications Backing Plate: Specifications Support Plate Mounting Bolts/Nuts 47 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications > Page 4615 Backing Plate: Service and Repair REMOVAL - BRAKE SUPPORT PLATE (1) Remove the wheel and tire assembly and the brake drum. (2) Remove the brake shoe assembly. (3) Remove the parking brake cable from parking brake lever. (4) Compress the parking brake cable retainer tabs. Then push retainer and cable through and out of support plate. (5) Disconnect the brake line at wheel cylinder. (6) Remove the wheel cylinder from support plate. (7) Remove the axle shaft. (8) Remove the bolts attaching the support plate to the axle and remove the support plate. INSTALLATION - BRAKE SUPPORT PLATE (1) Apply bead of silicone sealer around the axle mounting surface of the support plate. (2) Install the support plate on the axle flange. Tighten attaching bolts to 115 Nm (85 ft. lbs.). (3) Apply bead of silicone sealer around the wheel cylinder mounting surface and install the wheel cylinder. (4) Install the brake line in wheel cylinder. (5) Install the parking brake cable in support plate. (6) Install the axle shaft. (7) Connect the parking brake cable to the lever on secondary shoe and install the brake shoes on the support plate. (8) Adjust the brake shoes to the drum with brake gauge. (9) Install the brake drum and wheel and tire assembly. (10) Bleed the brake system. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications Brake Drum: Specifications Rear Drum Specifications 9" Rear Drum Nominal Diameter ................................................................................................................................ ............................................................... 9.00" Maximum Machine Limit ...................................................................................................................... ............................................................ 9.060" Discard Diameter ................................................................................................................................. .............................................................. 9.090" Runout Limit ........................................................................................................................................ ............................................................. 0.008" 10" Rear Drum Nominal Diameter ................................................................................................................................ ............................................................. 10.00" Maximum Machine Limit ...................................................................................................................... .......................................................... 10.060" Discard Diameter ................................................................................................................................. ............................................................ 10.090" Runout Limit ........................................................................................................................................ ............................................................. 0.008" 11" Rear Drum Nominal Diameter ................................................................................................................................ ............................................................. 11.00" Maximum Machine Limit ...................................................................................................................... .......................................................... 11.060" Discard Diameter ................................................................................................................................. ............................................................ 11.090" Runout Limit ........................................................................................................................................ ............................................................. 0.008" Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 4619 Brake Drum: Testing and Inspection DIAGNOSIS AND TESTING - BRAKE DRUM The maximum allowable diameter of the drum braking surface is indicated on the drum outer edge. Generally, a drum can be machined to a maximum of 1.52 mm (0.060 inch) oversize. Always replace the drum if machining would cause drum diameter to exceed the size limit indicated on the drum. BRAKE DRUM RUNOUT Measure drum diameter and runout with an accurate gauge. The most accurate method of measurement involves mounting the drum in a brake lathe and checking variation and runout with a dial indicator. Variations in drum diameter should not exceed 0.076 mm (0.003 inch). Drum runout should not exceed 0.20 mm (0.008 inch) out of round. Machine the drum if runout or variation exceed these values. Replace the drum if machining causes the drum to exceed the maximum allowable diameter. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 4620 Brake Drum: Service and Repair STANDARD PROCEDURE - BRAKE DRUM MACHINING The brake drums can be machined on a drum lathe when necessary. Initial machining cuts should be limited to 0.12 - 0.20 mm (0.005 - 0.008 inch) at a time as heavier feed rates can produce taper and surface variation. Final finish cuts of 0.025 to 0.038 mm (0.001 to 0.0015 inch) are recommended and will generally provide the best surface finish. Be sure the drum is securely mounted in the lathe before machining operations. A damper strap should always be used around the drum to reduce vibration and avoid chatter marks. The maximum allowable diameter of the drum braking surface is stamped or cast into the drum outer edge. CAUTION: Replace the drum if machining will cause the drum to exceed the maximum allowable diameter. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications Brake Shoe: Specifications As a general rule, riveted brake shoes should be replaced when worn to within 0.78 mm (1/32 inch) of the rivet heads. Bonded linings should be replaced when worn to a thickness of 1.6 mm (1/16 inch). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4624 Brake Shoe: Adjustments ADJUSTMENT- REAR DRUM BRAKE The rear drum brakes are equipped with a self-adjusting mechanism. Under normal circumstances, the only time adjustment is required is when the shoes are replaced, removed for access to other parts, or when one or both drums are replaced. Adjustment can be made with a standard brake gauge or with adjusting tool. Adjustment is performed with the complete brake assembly installed on the backing plate. ADJUSTMENT WITH BRAKE GAUGE (1) Be sure parking brakes are fully released. (2) Raise rear of vehicle and remove wheels and brake drums. (3) Verify that left and right automatic adjuster levers and cables are properly connected. (4) Insert brake gauge in drum. Expand gauge until gauge inner legs contact drum braking surface. Then lock cause in position. Adjusting Brake Shoes With Gauge (5) Reverse gauge and install it on brake shoes. Position gauge legs at shoe centers as shown. If gauge does not fit (too loose/too tight), adjust (6) Pull shoe adjuster lever away from adjuster screw star wheel. (7) Turn adjuster screw star wheel (by hand) to expand or retract brake shoes. Continue adjustment until gauge outside legs are light drag-fit on shoes. (8) Install brake drums and wheels and lower vehicle. (9) Drive vehicle and make one forward stop followed by one reverse stop. Repeat procedure 8 - 10 times to operate automatic adjusters and equalize adjustment. NOTE: Bring vehicle to complete standstill at each stop. Incomplete, rolling stops will not activate automatic adjusters. ADJUSTMENT WITH ADJUSTING TOOL (1) Be sure parking brake lever is fully released. (2) Raise vehicle so rear wheels can be rotated freely. (3) Remove plug from each access hole in brake support plates. (4) Loosen parking brake cable adjustment nut until there is slack in front cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4625 Fig. 6 Release type brake adjuster (5) Insert adjusting tool through support plate access hole and engage tool in teeth of adjusting screw star wheel. (6) Rotate adjuster screw star wheel (move tool handle upward) until slight drag can be felt when wheel is rotated. (7) Push and hold adjuster lever away from star wheel with thin screwdriver. (8) Back off adjuster screw star wheel until brake drag is eliminated. (9) Repeat adjustment at opposite wheel. Be sure adjustment is equal at both wheels. (10) Install support plate access hole plugs. (11) Adjust parking brake cable and lower vehicle. (12) Drive vehicle and make one forward stop followed by one reverse stop. Repeat procedure 8 - 10 times to operate automatic adjusters and equalize adjustment. NOTE: Bring vehicle to complete standstill at each stop. Incomplete, rolling stops will not activate automatic adjusters. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4626 Brake Shoe: Service and Repair REMOVAL - REAR BRAKE SHOES (1) Raise and support vehicle. (2) Remove wheel and tire assembly. (3) Remove clip nuts securing brake drum to wheel studs. (4) Remove drum. If drum is difficult to remove, remove rear plug from access hole in support plate. Back-off self adjusting by inserting a thin screwdriver into access hole and push lever away from adjuster screw star wheel. Then insert an adjuster tool into brake adjusting hole rotate adjuster star wheel to retract brake shoes. (5) Vacuum brake components to remove brake lining dust. (6) Remove shoe return springs with brake spring plier tool. (7) Remove adjuster cable. Slide cable eye off anchor pin. Then unhook and remove cable from adjuster lever. (8) Remove cable guide from secondary shoe and anchor plate from anchor pin. (9) Remove adjuster lever. Disengage lever from spring by sliding lever forward to clear pivot and work lever out from under spring. (10) Remove adjuster lever spring from pivot. (11) Disengage and remove shoe spring from brake shoes. (12) Disengage and remove adjuster screw assembly from brake shoes. (13) Remove brake shoe retainers, springs. (14) Remove secondary brake shoe from support plate. (15) Remove strut and spring. (16) Remove parking brake lever retaining clip from the secondary shoe and remove the lever. (17) Remove primary shoe from support plate. (18) Disengage parking brake lever from parking brake cable. INSTALLATION - REAR BRAKE SHOES (1) Clean and inspect individual brake components. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4627 (2) Lubricate anchor pin and brake shoe contact pads on support plate with high temperature grease or Lubriplate. (3) Lubricate adjuster screw socket, nut, button and screw thread surfaces with grease or Lubriplate. (4) Install the parking brake cable to the parking brake lever. (5) Install parking brake lever to the secondary shoe and install retaining clip. (6) Install primary shoe on support plate. Secure shoe with new spring retainers and pin. (7) Install spring on parking brake strut and engage strut in primary. (8) Install secondary shoe on support plate. Insert strut in shoe and guide shoe onto anchor pin. Temporarily secure shoe with retaining pin. (9) Install anchor plate and adjuster cable eyelet on support plate anchor pin. (10) Install cable guide in secondary shoe and position cable in guide. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4628 (11) Assemble adjuster screw. Then install and adjuster screw between the brake shoes. CAUTION: Be sure the adjuster screws are installed on the correct brake unit. The adjuster screws are marked L (left) and R (right) for identification. (12) Install adjuster lever and spring and connect adjuster cable to lever. (13) Install secondary shoe retainers and spring. (14) Install shoe spring. Connect spring to secondary shoe first. Then to primary shoe. (15) Verify adjuster operation. Pull adjuster cable upward, cable should lift lever and rotate star wheel. Be sure adjuster lever properly engages star wheel teeth. (16) Adjust brake shoes to drum with brake gauge. (17) Install wheel and tire assembly. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Wheel Cylinder Bolts 15 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Removal and Installation Wheel Cylinder: Service and Repair Removal and Installation REMOVAL (1) Remove wheel and tire assembly. (2) Remove brake drum. (3) Disconnect wheel cylinder brake line. (4) Remove brake shoe return springs and move shoes out of engagement with cylinder push rods. (5) Remove cylinder attaching bolts and remove cylinder from support plate. INSTALLATION (1) Apply bead of silicone sealer around the cylinder mounting surface of the support plate. (2) Install the cylinder mounting bolts and tighten to 20 Nm (15 ft. lbs.). (3) Connect the brake line to the cylinder. (4) Install the brake shoe return spring. (5) Install the brake drum. (6) Install the wheel and tire assembly. (7) Bleed the base brake system. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Removal and Installation > Page 4634 Wheel Cylinder: Service and Repair Disassembly and Assembly DISASSEMBLY (1) Remove push rods and boots. (2) Press pistons, cups and spring and expander out of cylinder bore. (3) Remove hand screw. ASSEMBLY (1) Lubricate wheel cylinder bore, pistons, piston cups and spring and expander with clean brake fluid. (2) Install first piston in cylinder bore. Then install first cup in bore and against piston. Be sure lip of piston cup is facing inward (toward spring and expander) and flat side is against piston. (3) Install spring and expander followed by remaining piston cup and piston. (4) Install boots on each end of cylinder and insert push rods in boots. (5) Install cylinder bleed screw. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Removal and Installation > Page 4635 Wheel Cylinder: Service and Repair Cleaning and Inspection CLEANING Clean the cylinder and pistons with clean brake fluid or brake cleaner only. Do not use any other cleaning agents. Dry the cylinder and pistons with compressed air. Do not use rags or shop towels to dry the cylinder components. Lint from cloth material will adhere to the cylinder bores and pistons. INSPECTION Inspect the cylinder bore. Light discoloration and dark stains in the bore are normal and will not impair cylinder operation. The cylinder bore can be lightly polished but only with crocus cloth. Replace the cylinder if the bore is scored, pitted or heavily corroded. Honing the bore to restore the surface is not recommended. Inspect the cylinder pistons. The piston surfaces should be smooth and free of scratches, scoring and corrosion. Replace the pistons if worn, scored, or corroded. Do attempt to restore the surface by sanding or polishing. Discard the old piston cups and the spring and expander. These parts are not reusable. The original dust boots may be reused but only if they are in good condition. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding Brake Bleeding: Service and Repair Master Cylinder Bleeding STANDARD PROCEDURE - MASTER CYLINDER BLEEDING A new master cylinder should be bled before installation on the vehicle. Required bleeding tools include bleed tubes and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from brake line. (1) Mount master cylinder in vise. Master Cylinder Bleeding - Typical (2) Attach bleed tubes to cylinder outlet ports. Then position each tube end into the reservoir. (3) Fill reservoir with fresh brake fluid. (4) Press cylinder pistons inward with wood dowel. Then release pistons and allow them to return under spring pressure. Continue bleeding operations until air bubbles are no longer visible in fluid Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 4641 Brake Bleeding: Service and Repair Standard Procedure - Manual Bleeding STANDARD PROCEDURE - MANUAL BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. 1. Remove reservoir filler caps and fill reservoir. 2. If calipers, or wheel cylinders were overhauled, open all caliper and wheel cylinder bleed screws. Then close each bleed screw as fluid starts to drip from it. Top off master cylinder reservoir once more before proceeding. 3. Attach one end of bleed hose to bleed screw and insert opposite end in glass container partially filled with brake fluid. Be sure end of bleed hose is immersed in fluid. 4. Open up bleeder, then have a helper press down the brake pedal. Once the pedal is down close the bleeder. Repeat bleeding until fluid stream is clear and free of bubbles. Then move to the next wheel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 4642 Brake Bleeding: Service and Repair Standard Procedure - Pressure Bleeding STANDARD PROCEDURE - PRESSURE BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Generally, a tank pressure of 15 - 20 psi is sufficient for bleeding. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding. Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system. Use adapter provided with the equipment or Adapter 6921. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Disc Brake Caliper Type Sliding Bore 2.75 in Mounting Pins 22 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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) Clean master cylinder reservoir and filler caps. (2) Remove reservoir filler cap and drain approximately 1/4 of fluid from reservoir. Use clean suction gun or similar device to drain fluid. (3) Raise and support vehicle. (4) Remove front wheel and tire assemblies. (5) Bottom caliper pistons in bores with large C-clamp. Position clamp frame on rear of caliper and clamp screw on outboard brake shoe. (6) Disconnect brake hose at caliper. Discard hose fitting washers if worn, or damaged. (7) With a screw driver pry up on the caliper spring and pull the spring out of the caliper holes. (8) Remove caliper and brake shoes from caliper. INSTALLATION (1) Install the brake shoes in the caliper. (2) Install the caliper and shoes over rotor and into ledges in steering knuckle. Be sure ends of brake shoes are properly seated on slide surfaces of ledges. (3) Install and tighten the caliper slide pins to 30 Nm (22 ft. lbs.). Start the slide pins by hand before tightening. Do not cross thread the pins. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4648 (4) Install the caliper spring into one caliper hole and under the adapter. Pull down on the opposite end of the spring and hold the end under the adapter. With a screw driver pry up on the spring to seat the spring into the other caliper hole. NOTE: Verify the spring is seated properly into the caliper holes. (5) Install the brake hose to the caliper with new seal washers and tighten fitting bolt to 24 Nm (18 ft. lbs.). CAUTION: Verify brake hose is not twisted or kinked before tightening fitting bolt. (6) Bleed the base brake system. (7) Install the wheel and tire assemblies. (8) Remove the supports and lower the vehicle. (9) Pump the brake pedal to seat brake shoes. (10) Fill the brake fluid reservoir. (11) Verify a firm pedal before moving the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4649 Brake Caliper: Service and Repair Disassembly and Assembly DISASSEMBLY (1) Drain old brake fluid out of caliper into drain pan. Piston Dust Boot (2) Remove piston dust boot. Use screwdriver to push boot out of groove. (3) Pad outboard shoe side of caliper interior with a minimum 1 inch thickness of shop towels. Towels will prevent piston damage when piston comes out of the caliper bore. (4) Remove caliper piston with short bursts of compressed air. Apply air pressure through fluid inlet port of caliper. CAUTION: Do not blow the piston out of the bore with sustained air pressure. This could result in a cracked piston. Use only enough air Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4650 pressure to ease the piston out. WARNING: NEVER ATTEMPT TO CATCH THE PISTON AS IT LEAVES THE BORE. THIS MAY RESULT IN PERSONAL INJURY. Caliper Piston Seal (5) Remove caliper piston seal with wood pencil or plastic tool. Do not use metal tools as they will scratch piston bore. (6) Remove caliper slide pin bushings and boots. (7) Remove caliper bleed screw and cap. ASSEMBLY (1) Lubricate slide pin boots and bushings with GE, or Dow silicone grease. Then install the boots and bushings in caliper. (2) Coat caliper piston bore, piston and new piston seal with clean brake fluid. Fig 19 Installing Caliper Piston Seal (3) Install new piston seal in caliper bore. Press seal into groove with finger. Lubricate seal and caliper bore with additional, fresh brake fluid after seal installation. (4) Apply light coat of GE 661, Dow 111 or similar silicone grease to edge and groove of piston and dust seal. Grease acts as corrosion protection for these areas. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4651 Sliding Boot Onto Piston (5) Slide new seal boot over piston until boot lip seats in piston groove. Snapping Boot Folds Into Place (6) Push retainer part of boot forward until folds in boot snap into place. Installing Caliper Piston And Boot (7) Start caliper piston in bore with a twisting motion. When piston is started in seal, push piston only part way into bore. Maintain uniform pressure on piston to avoid cocking it in bore. (8) Press caliper piston to bottom of bore. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4652 Seating Piston Dust Boot (9) Seat piston dust boot with Installer 8248 and Handle C-4171. Caliper Bleed Screw & Cap Installation (10) Install caliper bleed screw and bleed screw cap if removed. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4653 Brake Caliper: Service and Repair Cleaning and Inspection CLEANING Clean the caliper components with clean brake fluid or brake clean only. Wipe the caliper and piston dry with lint free towels or use low pressure compressed air. CAUTION: Do not use gasoline, kerosene, paint thinner, or similar solvents. These products may leave a residue that could damage the piston and seal. INSPECTION The piston is made from a phenolic resin (plastic material) and should be smooth and clean. The piston must be replaced if cracked or scored. Do not attempt to restore a scored piston surface by sanding or polishing. CAUTION: If the caliper piston is replaced, install the same type of piston in the caliper. Never inter-change phenolic resin and steel caliper pistons. The pistons, seals, seal grooves, caliper bore and piston tolerances are different. Fig 14 Honing Piston Bore The bore can be lightly polished with a brake hone to remove very minor surface imperfections. The caliper should be replaced if the bore is severely corroded, rusted, scored, or if polishing would increase bore diameter more than 0.025 mm (0.001 inch). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications BRAKE FLUID Specification ........................................................................................................................................ .................................................................. DOT 3 Standard .............................................................................................................................................. ........................................................... SAE J1703 NOTE: The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 4657 Brake Fluid: Service Precautions SAFETY PRECAUTIONS WARNING: Brake fluid may be irritating to the skin or eyes. In case of contact, take the following actions: * Eye Contact - rinse eyes thoroughly with water. * Skin Contact - wash skin with soap and water. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 4658 Brake Fluid: Testing and Inspection DIAGNOSIS AND TESTING - BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swollen rubber parts indicate the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If brake fluid is contaminated, drain and thoroughly flush system. Replace master cylinder, proportioning valve, caliper seals, wheel cylinder seals, Antilock Brakes hydraulic unit and all hydraulic fluid hoses. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications Brake Hose/Line: Specifications Brake Line Fittings Master Cylinder 170 in.lb Combination Valve 170 in.lb Wheel Cylinder 145 in.lb Brake Hose Front Fitting 145 in.lb Front Bolt 250 in.lb Rear Fitting 170 in.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Page 4662 Brake Hose/Line: Description and Operation DESCRIPTION Flexible rubber hose is used at both front brakes and at the rear axle junction block. Double walled steel tubing is used to connect the master cylinder to the major hydraulic braking components and then to the flexible rubber hoses. Double inverted style and ISO style flares are used on the brake lines. OPERATION The hoses and lines transmit the brake fluid hydraulic pressure to the calipers and or wheel cylinders. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Page 4663 Brake Hose/Line: Testing and Inspection DIAGNOSIS AND TESTING - BRAKE LINE AND HOSES Flexible rubber hose is used at both front brakes and at the rear axle junction block. Inspect the hoses whenever the brake system is serviced, at every engine oil change, or whenever the vehicle is in for service. Inspect the hoses for surface cracking, scuffing, or worn spots. Replace any brake hose immediately if the fabric casing of the hose is exposed due to cracks or abrasions. Also check brake hose installation. Faulty installation can result in kinked, twisted hoses, or contact with the wheels and tires or other chassis components. All of these conditions can lead to scuffing, cracking and eventual failure. The steel brake lines should be inspected periodically for evidence of corrosion, twists, kinks, leaks, or other damage. Heavily corroded lines will eventually rust through causing leaks. In any case, corroded or damaged brake lines should be replaced. Factory replacement brake lines and hoses are recommended to ensure quality, correct length and superior fatigue life. Care should be taken to make sure that brake line and hose mating surfaces are clean and free from nicks and burrs. Also remember that right and left brake hoses are not interchangeable. Use new copper seal washers at all caliper connections. Be sure brake line connections are properly made (not cross threaded) and tightened to recommended torque. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Double Inverted Flaring Brake Hose/Line: Service and Repair Double Inverted Flaring STANDARD PROCEDURE - DOUBLE INVERTED FLARING A preformed metal brake tube is recommended and preferred for all repairs. However, double-wall steel tube can be used for emergency repair when factory replacement parts are not readily available. (1) Cut off damaged tube with Tubing Cutter. (2) Ream cut edges of tubing to ensure proper flare. (3) Install replacement tube nut on the tube. (4) Insert tube in flaring tool. (5) Place gauge form over the end of the tube. (6) Push tubing through flaring tool jaws until tube contacts recessed notch in gauge that matches tube diameter. (7) Tighten the tool bar on the tube Cutting And Flaring Of Brake Fluid Tubing (8) Insert plug on gauge in the tube. Then swing compression disc over gauge and center tapered flaring screw in recess of compression disc. (9) Tighten tool handle until plug gauge is squarely seated on jaws of flaring tool. This will start the inverted flare. (10) Remove the plug gauge and complete the inverted flare. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Double Inverted Flaring > Page 4666 Brake Hose/Line: Service and Repair ISO Flaring STANDARD PROCEDURE - ISO FLARING A preformed metal brake tube is recommended and preferred for all repairs. However, double-wall steel tube can be used for emergency repair when factory replacement parts are not readily available. To make a ISO flare use a flaring tool kit. (1) Cut off damaged tube with Tubing Cutter. (2) Remove any burrs from the inside of the tube. (3) Install tube nut on the tube. (4) Position the tube in the flaring tool flush with the top of the tool bar. Then tighten the tool bar on the tube. (5) Install the correct size adaptor on the flaring tool yoke screw. (6) Lubricate the adaptor. (7) Align the adaptor and yoke screw over the tube. (8) Turn the yoke screw in-until the adaptor is squarely seated on the tool bar. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation Brake Proportioning/Combination Valve: Description and Operation DESCRIPTION The combination valve contains a pressure differential valve and switch and a proportioning valve. The combination valve/proportioning valve are not repairable and must be replaced as an assembly. The pressure differential switch is connected to the brake warning lamp. The switch is triggered by movement of the switch valve. The purpose of the switch is to monitor fluid pressure in the separate front/rear brake hydraulic circuits. A decrease or loss of fluid pressure in either hydraulic circuit will cause the switch valve to shuttle forward or rearward in response to the pressure differential. Movement of the switch valve will push the switch plunger upward. This closes the switch internal contacts completing the electrical circuit to the warning lamp. The switch valve may remain in an actuated position until repair restores system pressures to normal levels. OPERATION The combination valve contains a pressure differential valve and switch and a proportioning valve. The combination valve/proportioning valve are not repairable and must be replaced as an assembly. The proportioning valve is used to balance front-rear brake action at high decelerations. The valve allows normal fluid pressure during moderate braking. The valve only controls fluid pressure during high decelerations brake stops, when a percentage of rear weight is transferred to the front wheels. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Page 4670 Brake Proportioning/Combination Valve: Testing and Inspection DIAGNOSIS AND TESTING - COMBINATION VALVE (1) Have a helper sit in drivers seat to apply brake pedal and observe red brake warning light. (2) Raise vehicle on hoist. (3) Connect bleed hose to a rear wheel cylinder and immerse hose end in container partially filled with brake fluid. (4) Have helper press and hold brake pedal to floor and observe warning light. (a) If warning light illuminates, switch is operating correctly. (b) If light fails to illuminate, check circuit fuse, bulb, and wiring. The parking brake switch can be used to aid in identifying whether or not the brake light bulb and fuse is functional. Repair or replace parts as necessary and test differential pressure switch operation again. (5) If warning light still does not illuminate, switch is faulty. Replace combination valve assembly, bleed brake system and verify proper switch and valve operation. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Page 4671 Brake Proportioning/Combination Valve: Service and Repair REMOVAL (1) Disconnect wire from the pressure differential switch. (2) Disconnect rear brake lines from combination valve. (3) Remove the bolt from the combination valve and remove the valve. INSTALLATION (1) Install the combination valve to the bracket and tighten the mounting bolt to 20 - 27 Nm (15 - 20 ft. lbs.). If vehicle is equipped with ABS brakes tighten the bolt to 10 - 13 Nm (7 - 10 ft. lbs.). (2) Install the brake lines to the combination valve. (3) Tighten the brake line to 19 Nm (170 inch lbs.). (4) Connect the wire to the pressure differential switch. (5) Bleed brakes system . Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Specifications > Rear Wheel Antilock System Hydraulic Control Assembly - Antilock Brakes: Specifications RWAL Valve Mounting Bolt 15-20 ft.lb Brake Line Fittings 170 in.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Specifications > Rear Wheel Antilock System > Page 4676 Hydraulic Control Assembly - Antilock Brakes: Specifications ABS Assembly Bracket bolts 10-12 ft.lb Mounting Nuts 102 in.lb CAB Screws 36-42 in.lb Brake Line Fittings 170 in.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > Four Wheel Antilock Brake System Hydraulic Control Assembly - Antilock Brakes: Description and Operation Four Wheel Antilock Brake System DESCRIPTION The hydraulic control unit (HCU) consists of a valve body, pump, two accumulators and a motor. The assembly is mounted on the driver side inner fender under the hood. OPERATION The pump, motor, and accumulators are combined into an assembly attached to the valve body. The accumulators store the extra fluid which had to be dumped from the brakes. This is done to prevent the wheels from locking up. The pump provides the fluid volume needed and is operated by a DC type motor. The motor is controlled by the CAB. During normal braking, the HCU solenoid valves and pump are not activated. The master cylinder and power booster operate the same as a vehicle without an ABS brake system. The valve body contains the solenoid valves. The valves modulate brake pressure during antilock braking and are controlled by the CAB. The HCU provides three channel pressure control to the front and rear brakes. One channel controls the rear wheel brakes in tandem. The two remaining channels control the front wheel brakes individually. During antilock braking, the solenoid valves are opened and closed as needed. The valves are not static. They are cycled rapidly and continuously to modulate pressure and control wheel slip and deceleration. During antilock braking, solenoid valve pressure modulation occurs in three stages, pressure decrease, pressure hold, and pressure increase. The valves are all contained in the valve body portion of the HCU. PRESSURE DECREASE The inlet valve is closed and the outlet valve is opened during the pressure decrease cycle . A pressure decrease cycle is initiated when speed sensor signals indicate high wheel slip at one or more wheels. At this point, the CAB closes the inlet to prevent the driver from further increasing the brake pressure and locking the brakes. The CAB then opens the outlet valve, which also opens the return circuit to the accumulators. Fluid pressure is allowed to bleed off (decrease) as needed to prevent wheel lock. Once the period of high wheel slip has ended, the CAB closes the outlet valve and begins a pressure increase or hold cycle as needed. PRESSURE HOLD Both solenoid valves are closed in the pressure hold cycle . Fluid apply pressure in the control channel is maintained at a constant rate. The CAB maintains the hold cycle until sensor inputs indicate a pressure change is necessary. PRESSURE INCREASE The inlet valve is open and the outlet valve is closed during the pressure increase cycle. The pressure increase cycle is used to counteract unequal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > Four Wheel Antilock Brake System > Page 4679 wheel speeds. This cycle controls re-application of fluid apply pressure due to changing road surfaces or wheel speed. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > Four Wheel Antilock Brake System > Page 4680 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Rear Wheel Antilock Brakes DESCRIPTION The valve is located on the drivers side inner fender under the hood. The valve modulates hydraulic pressure to the rear brakes during an RWAL stop. OPERATION If the CAB senses that rear wheel speed deceleration is excessive, it will energize an isolation solenoid by providing battery voltage to the solenoid. This prevents a further increase of driver induced brake pressure to the rear wheels. If this initial action is not enough to prevent rear wheel lock-up, the CAB will momentarily energize a dump solenoid (the CAB energizes the dump solenoid by providing battery voltage to the solenoid). This opens the dump valve to vent a small amount of isolated rear brake pressure to an accumulator. The action of fluid moving to the accumulator reduces the isolated brake pressure at the wheel cylinders. The dump (pressure venting) cycle is limited to very short time periods (milliseconds). The CAB will pulse the dump valve until rear wheel deceleration matches the desired slip rate programmed into the CAB. The system will switch to normal braking once wheel locking tendencies are no longer present. A predetermined maximum number of consecutive dump cycles can be performed during any RWAL stop. If excessive dump cycles occur, a DTC will be set and stored in the CAB memory. If during a RWAL stop, the driver releases the brake pedal, the reset switch contacts will open. This signal to the CAB is an indication that pressure has equalized across the RWAL valve. The CAB will then reset the dump cycle counter in anticipation of the next RWAL stop. Additionally, any fluid stored in the accumulator will force its way past the dump valve, back into the hydraulic circuit and return to the master cylinder. A fuse internal to the CAB, provides a fail-safe device which prevents unwanted control over the isolation and dump solenoids. The fuse is in series with the isolation and dump solenoids output circuits. If the internal fuse is open, the CAB cannot provide voltage to energize either solenoid and RWAL stops are prevented. If the fuse is open, the braking system will operate normally but without antilock control over rear brake pressure. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Four Wheel Antilock Brake System Hydraulic Control Assembly - Antilock Brakes: Service and Repair Four Wheel Antilock Brake System REMOVAL (1) Disconnect battery negative cable. HCU Brake Lines (2) Remove the brake lines from HCU. (3) Push the harness connector locks to release the locks, then remove the connectors from the CAB. (4) Remove the nuts which attaches the assembly to the mounting bracket. (5) Remove the assembly from the vehicle. INSTALLATION (1) Install the antilock assembly into the bracket and tighten bolts to 14 - 15 Nm (10 - 12 ft. lbs). (2) Connect the CAB harnesses. (3) Connect the brake lines to the HCU. Tighten brake line fittings to 19 Nm (170 inch lbs.). (4) Connect battery. (5) Bleed brake system. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Four Wheel Antilock Brake System > Page 4683 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Rear Wheel Antilock Brake System REMOVAL (1) Remove RWAL valve harness connector from the RWAL controller. (2) Remove the brake lines from the valve. RWAL Valve (3) Remove the valve mounting bolt and remove the valve from the bracket. INSTALLATION (1) Position the valve on the bracket and install the mounting bolt. Tighten the mounting bolt to 20 27 Nm (15 - 20 ft. lbs.). (2) Install the brake lines and tighten to 19 Nm (170 inch lbs.). (3) Install the RWAL valve harness connector into the RWAL controller. (4) Bleed base brake system. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications Brake Master Cylinder: Specifications Master Cylinder Mounting Nuts 160 in.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 4687 Brake Master Cylinder: Description and Operation DESCRIPTION A two-piece master cylinder is used on all models. The cylinder body containing the primary and secondary pistons is made of aluminum. The removable fluid reservoir is made of nylon reinforced with glass fiber. The reservoir stores reserve brake fluid for the hydraulic brake circuits. The reservoir is the only serviceable component. The fluid compartments of the nylon reservoir are interconnected to permit fluid level equalization. However, the equalization feature does not affect circuit separation in the event of a front or rear brake malfunction. The reservoir compartments will retain enough fluid to operate the functioning hydraulic circuit. Care must be exercised when removing/installing the master cylinder connecting lines. The threads in the cylinder fluid ports can be damaged if care is not exercised. Start all brake line fittings by hand to avoid cross threading. The cylinder reservoir can be replaced when necessary. However, the aluminum body section of the master cylinder is not a repairable component. NOTE: If diagnosis indicates that an internal malfunction has occurred, the aluminum body section must be replaced as an assembly. OPERATION The master cylinder bore contains a primary and secondary piston. The primary piston supplies hydraulic pressure to the front brakes. The secondary piston supplies hydraulic pressure to the rear brakes. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 4688 Brake Master Cylinder: Testing and Inspection DIAGNOSIS AND TESTING - MASTER CYLINDER/POWER BOOSTER (1) Start engine and check booster vacuum hose connections. A hissing noise indicates vacuum leak. Correct any vacuum leak before proceeding. (2) Stop engine and shift transmission into Neutral. (3) Pump brake pedal until all vacuum reserve in booster is depleted. (4) Press and hold brake pedal under light foot pressure. The pedal should hold firm, if the pedal falls away master cylinder is faulty (internal leakage). (5) Start engine and note pedal action. It should fall away slightly under light foot pressure then hold firm. If no pedal action is discernible, power booster, vacuum supply, or vacuum check valve is faulty. Proceed to the POWER BOOSTER VACUUM TEST. (6) If the POWER BOOSTER VACUUM TEST passes, rebuild booster vacuum reserve as follows: Release brake pedal. Increase engine speed to 1500 rpm, close the throttle and immediately turn off ignition to stop engine. (7) Wait a minimum of 90 seconds and try brake action again. Booster should provide two or more vacuum assisted pedal applications. If vacuum assist is not provided, booster is faulty. POWER BOOSTER VACUUM TEST (1) Connect vacuum gauge to booster check valve with short length of hose and T-fitting . (2) Start and run engine at curb idle speed for one minute. (3) Observe the vacuum supply. If vacuum supply is not adequate, repair vacuum supply. (4) Clamp hose shut between vacuum source and check valve. (5) Stop engine and observe vacuum gauge. (6) If vacuum drops more than one inch HG (33 millibars) within 15 seconds, booster diaphragm or check valve is faulty. POWER BOOSTER CHECK VALVE TEST (1) Disconnect vacuum hose from check valve. (2) Remove check valve and valve seal from booster. (3) Use a hand operated vacuum pump for test. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 4689 (4) Apply 15 - 20 inches vacuum at large end of check valve. (5) Vacuum should hold steady. If gauge on pump indicates vacuum loss, check valve is faulty and should be replaced. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Procedure Brake Master Cylinder: Service and Repair Master Cylinder Bleeding Procedure STANDARD PROCEDURE - MASTER CYLINDER BLEEDING A new master cylinder should be bled before installation on the vehicle. Required bleeding tools include bleed tubes and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from brake line. (1) Mount master cylinder in vise. Master Cylinder Bleeding - Typical (2) Attach bleed tubes to cylinder outlet ports. Then position each tube end into the reservoir. (3) Fill reservoir with fresh brake fluid. (4) Press cylinder pistons inward with wood dowel. Then release pistons and allow them to return under spring pressure. Continue bleeding operations until air bubbles are no longer visible in fluid Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Procedure > Page 4692 Brake Master Cylinder: Service and Repair Master Cylinder Removal and Installation REMOVAL Master Cylinder (1) Remove brake lines from the master cylinder. (2) Remove mounting nuts from the master cylinder. (3) Remove master cylinder. INSTALLATION NOTE: If master cylinder is replaced bleed cylinder before installation. (1) Install the master cylinder on booster mounting studs. (2) Install the mounting nuts and tighten to 18 Nm (160 inch lbs.) (3) Install the brake lines and tighten to 19 Nm (170 inch lbs.) (4) Fill and bleed the base brake system Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Procedure > Page 4693 Brake Master Cylinder: Service and Repair Fluid Reservoir Removal and Installation REMOVAL (1) Remove reservoir cap and empty fluid into drain container. (2) Clamp cylinder body in vise with brass protective jaws. (3) Remove pins that retain reservoir to master cylinder. Use hammer and pin punch to remove pins. (4) Loosen reservoir from grommets with pry tool. Brake Fluid Reservoir Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Procedure > Page 4694 (5) Remove reservoir by rocking it to one side and pulling free grommets. Grommet Removal (6) Remove old grommets from cylinder body INSTALLATION CAUTION: Do not use any type of tool to install the grommets. Tools may cut, or tear the grommets creating a leak problem after installation. Install the grommets using finger pressure only. Brake Fluid Reservoir Grommet Installation (1) Lubricate new grommets with clean brake fluid and Install new grommets in cylinder body. Use finger pressure to install and seat grommets. (2) Start reservoir in grommets. Then rock reservoir back and forth while pressing downward to seat it in grommets. (3) Install pins that retain reservoir to cylinder body. (4) Fill and bleed master cylinder on bench before installation in vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Wheel Cylinder Bolts 15 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Removal and Installation Wheel Cylinder: Service and Repair Removal and Installation REMOVAL (1) Remove wheel and tire assembly. (2) Remove brake drum. (3) Disconnect wheel cylinder brake line. (4) Remove brake shoe return springs and move shoes out of engagement with cylinder push rods. (5) Remove cylinder attaching bolts and remove cylinder from support plate. INSTALLATION (1) Apply bead of silicone sealer around the cylinder mounting surface of the support plate. (2) Install the cylinder mounting bolts and tighten to 20 Nm (15 ft. lbs.). (3) Connect the brake line to the cylinder. (4) Install the brake shoe return spring. (5) Install the brake drum. (6) Install the wheel and tire assembly. (7) Bleed the base brake system. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Removal and Installation > Page 4700 Wheel Cylinder: Service and Repair Disassembly and Assembly DISASSEMBLY (1) Remove push rods and boots. (2) Press pistons, cups and spring and expander out of cylinder bore. (3) Remove hand screw. ASSEMBLY (1) Lubricate wheel cylinder bore, pistons, piston cups and spring and expander with clean brake fluid. (2) Install first piston in cylinder bore. Then install first cup in bore and against piston. Be sure lip of piston cup is facing inward (toward spring and expander) and flat side is against piston. (3) Install spring and expander followed by remaining piston cup and piston. (4) Install boots on each end of cylinder and insert push rods in boots. (5) Install cylinder bleed screw. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Removal and Installation > Page 4701 Wheel Cylinder: Service and Repair Cleaning and Inspection CLEANING Clean the cylinder and pistons with clean brake fluid or brake cleaner only. Do not use any other cleaning agents. Dry the cylinder and pistons with compressed air. Do not use rags or shop towels to dry the cylinder components. Lint from cloth material will adhere to the cylinder bores and pistons. INSPECTION Inspect the cylinder bore. Light discoloration and dark stains in the bore are normal and will not impair cylinder operation. The cylinder bore can be lightly polished but only with crocus cloth. Replace the cylinder if the bore is scored, pitted or heavily corroded. Honing the bore to restore the surface is not recommended. Inspect the cylinder pistons. The piston surfaces should be smooth and free of scratches, scoring and corrosion. Replace the pistons if worn, scored, or corroded. Do attempt to restore the surface by sanding or polishing. Discard the old piston cups and the spring and expander. These parts are not reusable. The original dust boots may be reused but only if they are in good condition. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Parking Brake Cable Parking Brake Cable: Service and Repair Front Parking Brake Cable REMOVAL - FRONT PARK BRAKE CABLE (1) Raise and support the vehicle. (2) Loosen the cable adjuster nut. (3) Pull cable through the body mount. (4) Remove support and lower vehicle. (5) Remove left kick panel. (6) Fold left front edge of floor covering rearward and remove cable grommet from floor pan. (7) Engage parking brake pedal and remove cable from park brake pedal assembly. (8) Pull the cable through the floor pan. (9) Remove cable from vehicle. INSTALLATION - FRONT PARK BRAKE CABLE (1) Insert front cable through floor pan and install grommet. (2) Insert cable retainer into hole at bottom of pedal assembly bracket and connect cable end. (3) Install kick panel. (4) Raise and support vehicle. (5) Insert the cable through the body mount. (6) Connect the cable to the tensioner. (7) Perform parking brake adjustment procedure. (8) Remove support and lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Parking Brake Cable > Page 4707 Parking Brake Cable: Service and Repair Rear Parking Brake Cable REMOVAL - REAR PARK BRAKE CABLES (1) Raise and support the vehicle. (2) Remove the rear wheel and tire assemblies. (3) Loosen tensioner adjuster nut. (4) Remove the right cable from the tensioner and pull the cable housing through the left cable connector. (5) Remove the left cable connector. (6) Pull both cables through the cable bracket. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Parking Brake Cable > Page 4708 (7) Remove the right cable mounting retainers from the stabilizer bar retainers and remove the cable from the differential housing. (8) Remove the brake drums. (9) Disconnect each cable from park brake lever. (10) Compress tabs on each cable housing retainer at the brake support plate. (11) Remove the cables from the brake support plates. INSTALLATION - REAR PARK BRAKE CABLES (1) Push each cable housing through the brake support plate hole until cable housing retainer tabs lock into place. NOTE: Pull on the cable housing to ensure it is locked into place. (2) Pull back on the end of the cable. Then push the cable in to engage the cable in the park brake lever. NOTE: Pull on the cable end to ensure it is attached to the park brake lever. (3) Install the brake drums. (4) Install right cable mounting retainers. (5) Push the cables housing through the cable bracket (6) Install the left cable onto the cable connector. (7) Push the right cable housing through the left cable connector and connect the cable to the tensioner. (8) Install the wheel and tire assemblies. (9) Perform park brake adjustment procedure. (10) Remove support and lower the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Service and Repair Parking Brake Pedal: Service and Repair REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Reach under the driver side outboard end of the instrument panel to access and unsnap the plastic retainer clip that secures the park brake release linkage rod to the lever on the back side of the park brake release handle. (3) Disengage the park brake release linkage rod end from the lever on the back of the park brake release handle. Park Brake Release Handle Remove/Install (4) Using a trim stick or another suitable wide flat-bladed tool, gently pry one of the park brake handle hinge tabs away from its pivot pin on the instrument panel. (5) While prying the park brake release handle hinge tab with one hand, use the other hand to pull the handle firmly down and away from the pivot pin. (6) Remove the park brake release handle from the instrument panel. INSTALLATION (1) Position the park brake release handle to the instrument panel. (2) Engage one of the park brake release handle hinge tabs with one of the pivot pins on the instrument panel. (3) Align the second park brake release handle hinge tab hinge over the second pivot pin on the instrument panel. (4) Press Manly on the park brake release handle over the second hinge tab until it snaps over the second pivot pin on the instrument panel. (5) Reach under the driver side outboard end of the instrument panel to access and engage the park brake release linkage rod end from the lever on the back of the park brake release handle. (6) Snap the plastic retainer clip that secures the park brake release linkage rod to the lever on the back side of the park brake release handle over the linkage rod. (7) Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Adjustments Parking Brake Tensioner: Adjustments NOTE: Tensioner adjustment is only necessary when the tensioner, or a cable has been replaced or disconnected for service. When adjustment is necessary, perform adjustment only as described in the following procedure. This is necessary to avoid faulty park brake operation. (1) Raise vehicle. (2) Back off cable tensioner adjusting nut create slack in cables. (3) Remove rear wheel/tire assemblies. Then remove brake drums. (4) Verify brakes are in good condition and operating properly. (5) Verify park brake cables operate freely and are not binding, or seized. (6) Check rear brake shoe adjustment with standard brake gauge. (7) Install drums and verify that drums rotate freely without drag. (8) Install wheel/tire assemblies. (9) Lower vehicle enough for access to park brake foot pedal. Then fully apply park brakes. NOTE: Leave park brakes applied until adjustment is complete. (10) Raise vehicle again. (11) Mark tensioner rod 6.35 mm (1/4 inch) from edge of tensioner if no mark is visible. NOTE: The rod is marked from the factory. (12) Tighten adjusting nut on tensioner until the 1/4 inch mark is no longer visible. CAUTION: Do not loosen, or tighten the tensioner adjusting nut for any reason after completing adjustment. (13) Lower vehicle until rear wheels are 15 - 20 cm (6 - 8 inch) off shop floor. (14) Release park brake foot pedal and verify that rear wheels rotate freely without drag. Then lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 BRAKE/PARK BRAKE INDICATOR A brake indicator is standard equipment on all instrument clusters. The brake indicator is located in the Information Center area of the instrument cluster; to the right of center. The brake indicator consists of a stenciled cutout of the word "BRAKE" and the International Control and Display Symbol icons for "Brake Failure" and "Parking Brake" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red lens behind the cutout in the opaque layer of the overlay causes the "BRAKE" text and the two icons to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by a Light Emitting Diode (LED) soldered onto the instrument cluster electronic circuit board. The brake indicator is serviced as a unit with the instrument cluster. The brake indicator gives an indication to the vehicle operator when the parking brake is applied, or when there are certain brake hydraulic system malfunctions. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming, and electronic messages received by the cluster from the Central Timer Module (CTM) and the Controller Antilock Brake (CAB) over the Programmable Communications Interface (PCI) data bus. The brake indicator Light Emitting Diode (LED) receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions; therefore, the LED will always be OFF when the ignition switch is in any position except ON or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the brake indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the brake indicator is illuminated by the instrument cluster for about four seconds as a bulb test. - Brake Lamp-ON Message - Each time the cluster receives a lamp-on message from the CTM or the CAB, the brake indicator will be illuminated. If the park brake is applied or not fully released, or if the pressures in the two halves of the split brake hydraulic system are not equal with the ignition switch in the ON position, the brake indicator is illuminated solid. The brake indicator will blink ON and OFF repeatedly when the park brake is applied or not fully released and the ignition switch is in the ON position if the automatic transmission is not in Park or Neutral. The indicator remains illuminated until the cluster receives lamp-OFF messages from both the CTM and the CAB, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the instrument cluster is put through the actuator test, the brake indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The park brake switch on the park brake pedal mechanism provides a hard wired ground input to the CTM circuitry through the park brake switch sense circuit whenever the park brake is applied or not fully released. The CTM then sends the proper lamp-ON or lamp-OFF messages to the instrument cluster. The brake pressure switch on the brake combination valve provides a hard wired ground input to the CAB circuitry through the brake pressure switch sense circuit whenever the pressures in the two halves of the split brake hydraulic system are unequal. The CAB then sends the proper lamp-ON or lamp-OFF messages to the instrument cluster. If the CAB sends a lamp-ON message after the bulb test, it indicates that the CAB has detected a brake hydraulic system malfunction and/or that the ABS system has become inoperative. The CAB will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. The park brake switch input to the CTM and the brake pressure switch input to the CAB can be diagnosed using conventional diagnostic tools and methods. For proper diagnosis of the antilock brake system, the CTM, the CAB, the PCI data bus, or the message inputs to the instrument cluster that control the brake indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications Brake Booster Type Tandem Diaphragm Mounting Nuts 250 in.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4722 Vacuum Brake Booster: Description and Operation DESCRIPTION All models use a tandem diaphragm, power brake booster. NOTE: The power brake booster is not a repairable component. The booster must be replaced as an assembly if diagnosis indicates a malfunction has occurred. OPERATION The booster unit consists of a single housing divided into two by a tandem diaphragm. The outer edge of the diaphragm is secured to the housing. The booster push rod, which connects the booster to the brake pedal and master cylinder, is attached to the center of the diaphragm. A check valve is used in the booster outlet connected to the engine intake manifold. Power assist is generated by utilizing a combination of vacuum and atmospheric pressure to boost brake assist. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4723 Vacuum Brake Booster: Service and Repair REMOVAL (1) Remove the master cylinder. (2) Disconnect the vacuum lines at booster. (3) Remove the clip securing the booster push rod to the brake pedal. (4) Remove the nuts from the booster mounting studs. (5) Remove the booster, spacer and gaskets from the front cowl panel. INSTALLATION (1) Position the spacer and gaskets on the booster studs. (2) Guide the booster studs into cowl panel holes and seat the booster on panel. (3) Install and tighten the booster attaching nuts to 28 Nm (250 inch lbs.). (4) Install the booster push rod on the brake pedal and install the clip. (5) Install the booster check valve if removed and connect vacuum hose to check valve. (6) Install the master cylinder. (7) Fill and bleed the brake system. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Controller Antilock Brake: > 08-035-00 > Nov > 00 > Brakes - Vehicle Surge While Speed Control is Engaged Controller Antilock Brake: Customer Interest Brakes - Vehicle Surge While Speed Control is Engaged NUMBER: 08-035-00 GROUP: Electrical DATE: Nov. 10, 2000 SUBJECT: Vehicle Surge While Speed Control Is Engaged OVERVIEW: This bulletin involves installing a new antilock brake control module. MODELS: 2001 (AN) Dakota 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH SPEED CONTROL (SALES CODE NHM) AND FOUR WHEEL ANTILOCK BRAKES (SALES CODE BGK) BUILT ON OR BEFORE THE ILLUSTRATED DATES: SYMPTOM/CONDITION: The vehicle surges while the speed control is engaged at 74 - 76 km/h (46 - 47 mph) and/or at 109 - 111 km/h (68 - 69 mph). DIAGNOSIS/REPAIR PROCEDURES: Road test the vehicle in a location where vehicle speeds of 74 - 76 km/h (46-47 mph) and/or 109 111 km/h (68 - 69 mph) can be maintained safely. Set the speed control at 74 - 76 km/h (46 - 47 mph) or at 109 - 111 km/h (68 - 69 mph). If the vehicle surges, disengage the speed control. If the vehicle still surges, further diagnosis is required. If the vehicle surges only while the speed control is engaged, perform the Repair Procedure. NOTE: DUE TO THE NATURE OF THIS CONDITION, IT MAY BE DIFFICULT TO DUPLICATE THE SYMPTOM. IF THE CUSTOMER INDICATES THAT THE VEHICLE SURGES AT 74 - 76 KM/H (46 - 47 MPH) AND/OR AT 109 - 111 KM/H (68 - 69 MPH) ONLY WHEN THE SPEED CONTROL IS ENGAGED, PERFORM THE REPAIR PROCEDURE. PARTS REQUIRED: NOTE: ANTILOCK BRAKE CONTROLLER AVAILABILITY IS RESTRICTED. THE STAR CENTER MUST BE CONTACTED TO GET AUTHORIZATION AND TO ORDER A CONTROLLER. THE STAR CENTER'S PHONE NUMBER IS 1-800-850-STAR (7827). WHEN THE AUTOMATED ANSWERING SYSTEM REQUESTS A GROUP SELECTION, SELECT BRAKES AND THEN SELECT THE KELSEY HAYES GROUP Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Controller Antilock Brake: > 08-035-00 > Nov > 00 > Brakes - Vehicle Surge While Speed Control is Engaged > Page 4733 EQUIPMENT REQUIRED: REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. NOTE: ONCE THE ANTILOCK BRAKE CONTROL MODULE (CAB) IS REPLACED, THE REAR AXLE TYPE AND TIRE SIZE MUST BE PROGRAMED INTO THE NEW CAB. 1. Disconnect battery negative cable. 2. Push the harness connector locks to release the locks, (Fig. 1) then remove the connectors from the CAB. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Controller Antilock Brake: > 08-035-00 > Nov > 00 > Brakes - Vehicle Surge While Speed Control is Engaged > Page 4734 3. Disconnect the pump motor connector (Fig. 2). 4. Remove screws attaching CAB to the Hydraulic control Unit (HCU) (Fig. 3). 5. Remove the CAB. 6. Place the new CAB onto the HCU (see Parts Required section). NOTE: ENSURE THE CAB SEAL IS IN POSITION BEFORE INSTALLATION. 7. Install the mounting screws and tighten to 4-4.7 N.m (36-42 in. lbs.). 8. Connect the pump motor harness. 9. Connect the harnesses to the CAB and lock the connectors. 10. Connect battery. NOTE: THE NEW CAB MUST HAVE THE TIRE SIZE AND AXLE TYPE PROGRAMMED INTO THE NEW CONTROLLER IN ORDER TO HAVE THE CONTROLLER COMMUNICATE THE PROPER VEHICLE SPEED. FAILURE TO PROPERLY PROGRAM THE REPLACEMENT CAB WILL RESULT IN A BLINKING ABS INDICATOR. 11. Inspect rear tires to determine tire sizes. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Controller Antilock Brake: > 08-035-00 > Nov > 00 > Brakes - Vehicle Surge While Speed Control is Engaged > Page 4735 12. Determine which rear axle type is used on this vehicle. Refer to the following graphics to help in identifying axle types (Fig. 4) (Fig. 5). 13. Using the DRBIII(R) select: MISC in the Antilock Brake menu. Then, SET PINION FACTOR. NOTE: THE DRBIII(R) MENU SCREEN CAN ONLY PROGRAM PRODUCTION SIZE TIRES THAT WERE CERTIFIED FOR THE VEHICLE WHEN THE VEHICLE WAS MANUFACTURED. IF THE TIRES ON THE VEHICLE DO NOT MATCH TIRE SIZES AVAILABLE ON THE DRBIII(R) MENU SCREEN, THEN THE TIRE ON THE VEHICLE WAS NEVER CERTIFIED FOR USAGE. 14. Turn the ignition switch to the RUN position (engine not running). 15. With the DRBIII(R), program the correct tire size and rear axle type. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Controller Antilock Brake: > 08-035-00 > Nov > 00 > Brakes - Vehicle Surge While Speed Control is Engaged > Page 4736 16. Road test the vehicle above 48 km/h (30 mph) for at least two minutes to ensure that the antilock brake system functions as designed. If the ABS warning lamp illuminates during the road test, further diagnosis is required. Refer to the appropriate Chassis Diagnostic Manual or the service information available in the MDS2. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Controller Antilock Brake: > 08-035-00 > Nov > 00 > Brakes - Vehicle Surge While Speed Control is Engaged Controller Antilock Brake: All Technical Service Bulletins Brakes - Vehicle Surge While Speed Control is Engaged NUMBER: 08-035-00 GROUP: Electrical DATE: Nov. 10, 2000 SUBJECT: Vehicle Surge While Speed Control Is Engaged OVERVIEW: This bulletin involves installing a new antilock brake control module. MODELS: 2001 (AN) Dakota 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH SPEED CONTROL (SALES CODE NHM) AND FOUR WHEEL ANTILOCK BRAKES (SALES CODE BGK) BUILT ON OR BEFORE THE ILLUSTRATED DATES: SYMPTOM/CONDITION: The vehicle surges while the speed control is engaged at 74 - 76 km/h (46 - 47 mph) and/or at 109 - 111 km/h (68 - 69 mph). DIAGNOSIS/REPAIR PROCEDURES: Road test the vehicle in a location where vehicle speeds of 74 - 76 km/h (46-47 mph) and/or 109 111 km/h (68 - 69 mph) can be maintained safely. Set the speed control at 74 - 76 km/h (46 - 47 mph) or at 109 - 111 km/h (68 - 69 mph). If the vehicle surges, disengage the speed control. If the vehicle still surges, further diagnosis is required. If the vehicle surges only while the speed control is engaged, perform the Repair Procedure. NOTE: DUE TO THE NATURE OF THIS CONDITION, IT MAY BE DIFFICULT TO DUPLICATE THE SYMPTOM. IF THE CUSTOMER INDICATES THAT THE VEHICLE SURGES AT 74 - 76 KM/H (46 - 47 MPH) AND/OR AT 109 - 111 KM/H (68 - 69 MPH) ONLY WHEN THE SPEED CONTROL IS ENGAGED, PERFORM THE REPAIR PROCEDURE. PARTS REQUIRED: NOTE: ANTILOCK BRAKE CONTROLLER AVAILABILITY IS RESTRICTED. THE STAR CENTER MUST BE CONTACTED TO GET AUTHORIZATION AND TO ORDER A CONTROLLER. THE STAR CENTER'S PHONE NUMBER IS 1-800-850-STAR (7827). WHEN THE AUTOMATED ANSWERING SYSTEM REQUESTS A GROUP SELECTION, SELECT BRAKES AND THEN SELECT THE KELSEY HAYES GROUP Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Controller Antilock Brake: > 08-035-00 > Nov > 00 > Brakes - Vehicle Surge While Speed Control is Engaged > Page 4742 EQUIPMENT REQUIRED: REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. NOTE: ONCE THE ANTILOCK BRAKE CONTROL MODULE (CAB) IS REPLACED, THE REAR AXLE TYPE AND TIRE SIZE MUST BE PROGRAMED INTO THE NEW CAB. 1. Disconnect battery negative cable. 2. Push the harness connector locks to release the locks, (Fig. 1) then remove the connectors from the CAB. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Controller Antilock Brake: > 08-035-00 > Nov > 00 > Brakes - Vehicle Surge While Speed Control is Engaged > Page 4743 3. Disconnect the pump motor connector (Fig. 2). 4. Remove screws attaching CAB to the Hydraulic control Unit (HCU) (Fig. 3). 5. Remove the CAB. 6. Place the new CAB onto the HCU (see Parts Required section). NOTE: ENSURE THE CAB SEAL IS IN POSITION BEFORE INSTALLATION. 7. Install the mounting screws and tighten to 4-4.7 N.m (36-42 in. lbs.). 8. Connect the pump motor harness. 9. Connect the harnesses to the CAB and lock the connectors. 10. Connect battery. NOTE: THE NEW CAB MUST HAVE THE TIRE SIZE AND AXLE TYPE PROGRAMMED INTO THE NEW CONTROLLER IN ORDER TO HAVE THE CONTROLLER COMMUNICATE THE PROPER VEHICLE SPEED. FAILURE TO PROPERLY PROGRAM THE REPLACEMENT CAB WILL RESULT IN A BLINKING ABS INDICATOR. 11. Inspect rear tires to determine tire sizes. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Controller Antilock Brake: > 08-035-00 > Nov > 00 > Brakes - Vehicle Surge While Speed Control is Engaged > Page 4744 12. Determine which rear axle type is used on this vehicle. Refer to the following graphics to help in identifying axle types (Fig. 4) (Fig. 5). 13. Using the DRBIII(R) select: MISC in the Antilock Brake menu. Then, SET PINION FACTOR. NOTE: THE DRBIII(R) MENU SCREEN CAN ONLY PROGRAM PRODUCTION SIZE TIRES THAT WERE CERTIFIED FOR THE VEHICLE WHEN THE VEHICLE WAS MANUFACTURED. IF THE TIRES ON THE VEHICLE DO NOT MATCH TIRE SIZES AVAILABLE ON THE DRBIII(R) MENU SCREEN, THEN THE TIRE ON THE VEHICLE WAS NEVER CERTIFIED FOR USAGE. 14. Turn the ignition switch to the RUN position (engine not running). 15. With the DRBIII(R), program the correct tire size and rear axle type. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Controller Antilock Brake: > 08-035-00 > Nov > 00 > Brakes - Vehicle Surge While Speed Control is Engaged > Page 4745 16. Road test the vehicle above 48 km/h (30 mph) for at least two minutes to ensure that the antilock brake system functions as designed. If the ABS warning lamp illuminates during the road test, further diagnosis is required. Refer to the appropriate Chassis Diagnostic Manual or the service information available in the MDS2. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Page 4746 Controller Antilock Brake: Specifications Controller Mounting Screws 53 in.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > EBC 325 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > EBC 325 > Page 4749 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > Page 4750 Controller Antilock Brake: Diagrams Controller Antilock Brake C1 Controller Antilock Brake C2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > Page 4751 Controller Antilock Brake: Description and Operation CONTROLLER REAR WHEEL ANTILOCK BRAKES Fig. 3 RWAL Cab The Controller Antilock Brakes (CAB) is a microprocessor which handles testing, monitoring and controlling the ABS brake system operation. The CAB functions are: Perform self-test diagnostics. - Monitor the RWAL brake system for proper operation. - Control the RWAL valve solenoids. Fig. 4 CAB/HCU The CAB is mounted on the top of the hydraulic control unit. The CAB operates the ABS system and is separate from other vehicle electrical circuits. CAB voltage source is through the ignition switch in the RUN position. NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. For axle type refer to Differential and Driveline. System Self-test When the ignition switch is turned-ON the microprocessor RAM and ROM are tested. If an error occurs during the test, a DTC will be set into the RAM memory. However it is possible the DTC will not be stored in memory if the error has occurred in the RAM module were the DTC's are Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > Page 4752 stored. Also it is possible a DTC may not be stored if the error has occurred in the ROM which signals the RAM to store the DTC. The CAB contains a self check program that illuminates the ABS warning light when a system fault is detected. Faults are stored in a diagnostic program memory and are accessible with the DRB scan tool. ABS faults remain in memory until cleared, or until after the vehicle is started approximately 50 times. Stored faults are not erased if the battery is disconnected. CAB Inputs The CAB continuously monitors the speed of the differential ring gear by monitoring signals generated by the rear wheel speed sensor. The CAB determines a wheel locking tendency when it recognizes the ring gear is decelerating too rapidly. The CAB monitors the following inputs to determine when a wheel locking tendency may exists: Rear Wheel Speed Sensor - Brake Lamp Switch - Brake Warning Lamp Switch - Reset Switch - 4WD Switch (If equipped) CAB Outputs The CAB controls the following outputs for antilock braking and brake warning information: RWAL Valve - ABS Warning Lamp - Brake Warning Lamp Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > Page 4753 Controller Antilock Brake: Service and Repair REMOVAL NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. For axle type refer to Differential and Driveline. Fig. 5 Harness Connector Locks 1. Push the CAB harness connector lock to release the lock and remove the connector from the controller. Fig. 6 Pump Motor Connector 2. Remove the RWAL valve harness and the pump motor connectors from the controller. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > Page 4754 Fig. 7 RWAL Controller 3. Remove the controller mounting screws and remove the controller from the mounting bracket. INSTALLATION NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. 1. Position the controller on the bracket. 2. Install the mounting screws and tighten to 6 Nm (53 in. lbs). 3. Install the RWAL valve harness connector into the controller. 4. Install the CAB harness connector into the controller and push down on the connector lock. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Four Wheel Antilock Brake System Wheel Speed Sensor: Specifications Wheel Speed Sensors Front Sensor Bolt 190 in.lb Rear Sensor Bolt 200 in.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Four Wheel Antilock Brake System > Page 4760 Wheel Speed Sensor: Specifications Wheel Speed Sensor Mounting Bolt 200 in.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations Wheel Speed Sensor: Component Locations Front Wheel Speed Sensor/Tone Wheels Rear Wheel Speed Sensors/Tone Wheels Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4763 Wheel Speed Sensor: Connector Locations Left Front Wheel Speed Sensor Connector Right Front Wheel Speed Sensor Connector Rear Wheel Speed Sensor Connector Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 4764 Wheel Speed Sensor: Diagrams Left Front Wheel Speed Sensor (Sensor Side) Left Front Wheel Speed Sensor Rear Wheel Speed Sensor Right Front Wheel Speed Sensor (Sensor Side) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 4765 Right Front Wheel Speed Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Rear Wheel Antilock Brake System Wheel Speed Sensor: Description and Operation Rear Wheel Antilock Brake System DESCRIPTION The rear Wheel Speed Sensor (WSS) is mounted in the rear differential housing. The exciter ring is press fitted onto the differential carrier next to the final drive ring gear. For replacement procedure of the exciter ring. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Rear Wheel Antilock Brake System > Page 4768 Wheel Speed Sensor: Description and Operation Wheel Speed Sensor OPERATION The WSS consists of a magnet surrounded by windings from a single strand of wire. The sensor sends a small AC signal to the CAB. This signal is generated by magnetic induction. The magnetic induction is created when a toothed sensor ring (exciter ring or tone wheel) passes the stationary magnetic WSS. When the ring gear is rotated, the exciter ring passes the tip of the WSS. As the exciter ring tooth approaches the tip of the WSS, the magnetic lines of force expand, causing the magnetic field to cut across the sensor's windings. This, in turn causes current to flow through the WSS circuit in one direction. When the exciter ring tooth moves away from the sensor tip, the magnetic lines of force collapse cutting the winding in the opposite direction. This causes the current to flow in the opposite direction. Every time a tooth of the exciter ring passes the tip of the WSS, an AC signal is generated. Each AC signal (positive to negative signal or sinewave) is interpreted by the CAB. It then compares the frequency of the sinewave to a time value to calculate vehicle speed. The CAB continues to monitor the frequency to determine a deceleration rate that would indicate a possible wheel-locking tendency. The signal strength of any magnetic induction sensor is directly affected by: - Magnetic field strength; the stronger the magnetic field, the stronger the signal - Number of windings in the sensor; more windings provide a stronger signal - Exciter ring speed; the faster the exciter ring/tone wheel rotates, the stronger the signal will be - Distance between the exciter ring teeth and WSS; the closer the WSS is to the exciter ring/tone wheel, the stronger the signal will be The rear WSS is not adjustable. A clearance specification has been established for manufacturing tolerances. If the clearance is not within these specifications, then either the WSS or other components may be damaged. The clearance between the WSS and the exciter ring is 0.005 0.050 inch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Rear Wheel Antilock Brake System > Page 4769 The assembly plant performs a "Rolls Test" on every vehicle that leaves the assembly plant. One of the test performed is a test of the WSS. To properly test the sensor, the assembly plant connects test equipment to the Data Link Connector (DLC). This connector is located to the right of the steering column and attached to the lower portion of the instrument panel. The rolls test terminal is spliced to the WSS circuit. The vehicle is then driven on a set of rollers and the WSS output is monitored for proper operation. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 REMOVAL - 2WD (1) Raise and support vehicle. (2) Remove bolt attaching sensor to the steering knuckle. (3) Remove clamps securing sensor wire to control arm and inner fender panel. (4) In engine compartment, disconnect sensor wire from harness and remove sensor. INSTALLATION - 2WD (1) Position sensor in the knuckle and install sensor attaching bolts. Tighten bolts to 21 Nm (190 inch lbs.). (2) Secure sensor wire retaining clamps to control arm and fender panel. (3) In engine compartment, connect sensor wire to harness connector. Make sure wire is routed away from hot or rotating underhood components. (4) Turn steering wheel back and forth to verify that wire is clear of steering and suspension components. (5) Remove supports and lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 4772 Wheel Speed Sensor: Service and Repair Rear REAR WHEEL SPEED SENSOR REMOVAL (1) Raise vehicle on hoist. (2) Remove brake line mounting nut and remove the brake line from the sensor stud. (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 O-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 (200 inch lbs.). (6) Install the brake line on the sensor stud and install the nut. (7) Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Fig. 1 Battery Temperature Sensor Location The battery temperature sensor is located under vehicle battery and is attached to a mounting hole on battery tray. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 4778 Battery Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 4779 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and 02 sensor heater tests). Most OBD II monitors are disabled below 20 degrees F. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 4780 Battery Temperature Sensor: Testing and Inspection Tests 1 - 2 SYMPTOM CHECKING THE AMBIENT/BATTERY TEMPERATURE SENSOR POSSIBLE CAUSES - Ambient/Battery temperature sensor - Ambient/Battery temperature sensor (Out Of Calibration) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 4781 Battery Temperature Sensor: Service and Repair Fig. 1 Battery Temperature Sensor Location REMOVAL The battery temperature sensor is located under vehicle battery (Fig. 1) and is attached to a mounting hole on battery tray. 1. Remove battery. Refer to Battery for procedures. 2. Disconnect sensor pigtail harness from engine wire harness. Sensor pigtail harness is clipped to vehicle near its electrical connector. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION The battery temperature sensor is located under vehicle battery (Fig. 1) and is attached to a mounting hole on battery tray. 1. Feed pigtail harness through hole in top of battery tray and press sensor into top of battery tray. 2. Connect pigtail harness. 3. Install battery. Refer to Battery for procedures. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Power Distribution Center Starter Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4786 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4787 Starter Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4788 Engine Starter Motor Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4789 Starter Relay: Description and Operation The starter relay is an electromechanical device that switches battery current to the pull-in coil of the starter solenoid when ignition switch is turned to Start position. The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. See PDC cover for relay identification and location. The starter relay is a International Standards Organization (ISO) relay. Relays conforming to ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The starter relay cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When electromagnetic coil is energized, it draws the movable contact away from normally closed fixed contact, and holds it against the other (normally open) fixed contact. When electromagnetic coil is de-energized, spring pressure returns movable contact to normally closed position. The resistor or diode is connected in parallel with electromagnetic coil within relay, and helps to dissipate voltage spikes produced when coil is de-energized. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4790 Starter Relay: Testing and Inspection Fig. 11 Starter Relay The starter relay (Fig. 11) is located in Power Distribution Center (PDC). Refer to PDC cover for relay identification and location. 1. Remove starter relay from PDC. 2. A relay in de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace faulty relay. 4. Connect 12V battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, perform Relay Circuit Test that follows. If not OK, replace faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair open circuit to fuse in PDC as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to common feed terminal (30) in the energized position. This terminal supplies battery voltage to starter solenoid field coils. There should be continuity between cavity for relay terminal 87 and starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair open circuit to starter solenoid as required. 4. The coil battery terminal (86) is connected to electromagnet in relay. It is energized when ignition switch is held in Start position. On vehicles with manual transmission, clutch pedal must be fully depressed for this test. Check for battery voltage at cavity for relay terminal 86 with ignition switch in Start position, and no voltage when ignition switch is released to ON position. If OK, go to Step 5. If not OK with automatic transmission, check for open or short circuit to ignition switch and repair, if required. If circuit to ignition switch is OK, refer to Ignition Switch and Key Lock Cylinder. If not OK with a manual transmission, check circuit between relay and clutch pedal position switch for open or a short. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. On vehicles with manual transmission, it is grounded at all times. On vehicles with automatic transmission, it is grounded through park/neutral position switch only when gearshift selector lever is in Park or Neutral positions. Check for continuity to ground at cavity for relay terminal 85. If not OK with manual transmission, repair circuit to ground as required. If not OK with automatic transmission, check for pen or short circuit to park/neutral position switch and repair, if required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4791 Starter Relay: Service and Repair REMOVAL 1. Disconnect and isolate negative battery cable. Fig. 12 Power Distribution Center 2. Remove cover from Power Distribution Center (PDC) (Fig. 12). 3. See fuse and relay layout label affixed to underside of PDC cover for starter relay identification and location. 4. Remove starter relay from PDC. INSTALLATION 1. See fuse and relay layout label affixed to underside of PDC cover for proper starter relay location. 2. Position starter relay in proper receptacle in PDC. 3. Align starter relay terminals with terminal cavities in PDC receptacle. 4. Push down firmly on starter relay until terminals are fully seated in terminal cavities in PDC receptacle. 5. Install cover onto PDC. 6. Reconnect negative battery cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications Battery Cable: Specifications Battery Cable Eyelet Nut at Solenoid (large nut) .................................................................................................................................. 14 Nm (120 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications > Page 4796 Battery Cable: Description and Operation Fig. 20 Battery Cables The battery cables (Fig. 20) are large gauge, stranded copper wires sheathed within a heavy plastic or synthetic rubber insulating jacket. The wire used in the battery cables combines excellent flexibility and reliability with high electrical current carrying capacity. Refer to Wiring Diagrams for the location of the proper battery cable wire gauge information. The battery cables cannot be repaired and, if damaged or faulty they must be replaced. Both the battery positive and negative cables are available for service replacement only as a unit with the battery positive cable wire harness or the battery negative cable wire harness, which may include portions of the wiring circuits for the generator and other components on some models. Refer to Wiring Diagrams for the location of more information on the various wiring circuits included in the battery cable wire harnesses for the vehicle being serviced. The battery cables feature a stamped brass clamping type female battery terminal crimped onto one end of the battery cable wire and then solder-dipped. A square headed pinch-bolt and hex nut are installed at the open end of the female battery terminal clamp. The battery positive cable also includes a red molded rubber protective cover for the female battery terminal clamp. Large eyelet type terminals are crimped onto the opposite end of the battery cable wire and then solder-dipped. The battery positive cable wires have a red insulating jacket to provide visual identification and feature a larger female battery terminal clamp to allow connection to the larger battery positive terminal post. The battery negative cable wires have a black insulating jacket and a smaller female battery terminal clamp. The battery cables connect the battery terminal posts to the vehicle electrical system. These cables also provide a return path for electrical current generated by the charging system for restoring the voltage potential of the battery. The female battery terminal clamps on the ends of the battery cable wires provide a strong and reliable connection of the battery cable to the battery terminal posts. The terminal pinch bolts allow the female terminal clamps to be tightened around the male terminal posts on the top of the battery. The eyelet terminals secured to the ends of the battery cable wires opposite the female battery terminal clamps provide secure and reliable connection of the battery to the vehicle electrical system. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications > Page 4797 Battery Cable: Testing and Inspection A voltage drop test will determine if there is excessive resistance in the battery cable terminal connections or the battery cables. If excessive resistance is found in the battery cable connections, the connection point should be disassembled, cleaned of all corrosion or foreign material, then reassembled. Following reassembly, check the voltage drop for the battery cable connection and the battery cable again to confirm repair. When performing the voltage drop test, it is important to remember that the voltage drop is giving an indication of the resistance between the two points at which the voltmeter probes are attached. EXAMPLE: When testing the resistance of the battery positive cable, touch the voltmeter leads to the battery positive cable terminal clamp and to the battery positive cable eyelet terminal at the starter solenoid B(+) terminal stud. If you probe the battery positive terminal post and the battery positive cable eyelet terminal at the starter solenoid B(+) terminal stud, you are reading the combined voltage drop in the battery positive cable terminal clamp-to-terminal post connection and the battery positive cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Fig. 1 Battery Temperature Sensor Location The battery temperature sensor is located under vehicle battery and is attached to a mounting hole on battery tray. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 4801 Battery Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 4802 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and 02 sensor heater tests). Most OBD II monitors are disabled below 20 degrees F. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 4803 Battery Temperature Sensor: Testing and Inspection Tests 1 - 2 SYMPTOM CHECKING THE AMBIENT/BATTERY TEMPERATURE SENSOR POSSIBLE CAUSES - Ambient/Battery temperature sensor - Ambient/Battery temperature sensor (Out Of Calibration) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 4804 Battery Temperature Sensor: Service and Repair Fig. 1 Battery Temperature Sensor Location REMOVAL The battery temperature sensor is located under vehicle battery (Fig. 1) and is attached to a mounting hole on battery tray. 1. Remove battery. Refer to Battery for procedures. 2. Disconnect sensor pigtail harness from engine wire harness. Sensor pigtail harness is clipped to vehicle near its electrical connector. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION The battery temperature sensor is located under vehicle battery (Fig. 1) and is attached to a mounting hole on battery tray. 1. Feed pigtail harness through hole in top of battery tray and press sensor into top of battery tray. 2. Connect pigtail harness. 3. Install battery. Refer to Battery for procedures. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Holddown Battery Tray: Service and Repair Battery Holddown REMOVAL 1. Turn the ignition switch to the OFF position. Be certain that all electrical accessories are turned OFF. 2. Loosen the battery negative cable terminal clamp pinch-bolt hex nut. 3. Disconnect the battery negative cable terminal clamp from the battery negative terminal post. If necessary use a battery terminal puller to remove the terminal clamp from the battery post. 4. Disconnect the battery positive cable terminal clamp from the battery positive terminal post. If necessary, use a battery terminal puller to remove the terminal clamp from the battery post. Fig. 19 Battery Hold Downs Remove/Install 5. Remove the two hold down bolts that secure the hold down strap/battery thermal guard unit to the U-nuts in the battery tray (Fig. 19). 6. Remove the hold down strap/battery thermal guard unit from the top of the battery case. INSTALLATION 1. Clean and inspect the battery hold down hardware. 2. Install the hold down strap/battery thermoguard unit over the top of the battery case. 3. Install and tighten the two hold down bolts that secure the hold down strap/battery thermoguard unit to the U-nuts in the battery tray. Tighten the bolts to 2.1 Nm (19 in. lbs.). 4. Reconnect the battery positive cable terminal clamp to the battery positive terminal post. Tighten the terminal clamp pinch-bolt hex nut to 7.9 Nm (70 in. lbs.). 5. Reconnect the battery negative cable terminal clamp to the battery negative terminal post. Tighten the terminal clamp pinch-bolt hex nut to 7.9 Nm (70 in. lbs.). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Holddown > Page 4809 Battery Tray: Service and Repair Battery Tray REMOVAL 1. Remove the battery from the battery tray. 2. Remove the Power Distribution Center (PDC) from the stanchions on the rear of the battery tray. Fig. 26 Battery Tray Remove/Install 3. Remove the two screws that secure the inboard side of the battery tray to the battery tray support (Fig. 26). 4. Remove the two screws that secure the outboard side of the battery tray to the front extension of the left front wheelhouse inner panel. 5. Remove the one screw that secures the front of the battery tray to the front closure panel on the left side of the radiator yoke. 6. Remove the battery temperature sensor from the battery tray. 7. Remove the battery tray from the battery tray support and the front extension of the left front wheelhouse inner panel. 8. Remove the one screw that secures the rear of the battery tray support to the front extension of the left front wheelhouse inner panel. 9. Remove the two screws that secure the front of the battery tray support to the left side of the radiator yoke. 10. Remove the battery tray support from the left front wheelhouse inner panel and the left side of the radiator yoke INSTALLATION 1. Clean and inspect the battery tray. 2. Position the battery tray support onto the left front wheelhouse inner panel and the left side of the radiator yoke. 3. Install and tighten the two screws that secure the battery tray support to the left side of the radiator yoke. Tighten the screws to 11.3 Nm (100 in. lbs.). 4. Install and tighten the one screw that secures the rear of the battery tray support to the front extension of the left front wheelhouse inner panel. Tighten the screw to 11.3 Nm (100 in. lbs.). 5. Install the battery temperature sensor onto the battery tray. 6. Position the battery tray onto the battery tray support and the front extension of the left front wheelhouse inner panel. Be certain that the battery temperature sensor wiring is properly routed. 7. Install and tighten the two screws (rear screw first) that secure the outboard side of the battery tray to the front extension of the left front wheelhouse inner panel.Tighten the screws to 12.4 Nm (110 in. lbs.). 8. Install and tighten the two screws that secure the inboard side of the battery tray to the battery tray support. Tighten the screws to 12.4 Nm (110 in. lbs.). 9. Install and tighten the one screw that secures the front of the battery tray to the front closure panel on the left side of the radiator yoke. Tighten the Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Holddown > Page 4810 screw to 12.4 Nm (110 in. lbs.). 10. Install the Power Distribution Center (PDC) onto the stanchions on the rear of the battery tray. 11. Install the battery onto the battery tray. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications Alternator: Electrical Specifications Denso 56029700AA Rated Sae Amps ................................................................................................ ................................................................................................................ 136 Minimum Test Amps ............................................................................................................................ ............................................................................. 100 Denso 56029914AA Rated Sae Amps ................................................................................................ ................................................................................................................ 160 Minimum Test Amps ............................................................................................................................ ................................................................................. - Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications > Page 4816 Alternator: Mechanical Specifications Generator Vertical Mounting Bolt ........................................................................................................................................................... 55 Nm (40 Ft. Lbs) Generator (Long) Horizontal Mounting Bolt .......................................................................................................................................... 55 Nm (40 Ft. Lbs) Generator (Short) Horizontal Mounting Bolt .......................................................................................................................................... 74 Nm (55 Ft. Lbs) Generator B+ Output Cable Terminal Nut ............................................................................................................................................ 12 Nm (108 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4817 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4818 Generator Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4819 Alternator: Service Precautions WARNING: DISCONNECT NEGATIVE CABLE FROM BATTERY BEFORE REMOVING BATTERY OUTPUT WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO DO SO CAN RESULT IN INJURY OR DAMAGE TO ELECTRICAL SYSTEM. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4820 Alternator: Description and Operation The generator is belt-driven by the engine using a serpentine type drive belt. 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 terminal. Although the generators appear the same externally, different generators with different output ratings are used on this vehicle. Be certain that the replacement generator has the same output rating and part number as the original unit. Refer to Generator Ratings in the Specifications for amperage ratings and part numbers. Noise emitting from the generator may be caused by: worn, loose or defective bearings; a loose or defective drive pulley; incorrect, worn, damaged or misadjusted fan drive belt; loose mounting bolts; a misaligned drive pulley or a defective stator or diode. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4821 Alternator: Service and Repair REMOVAL WARNING: DISCONNECT NEGATIVE CABLE FROM BATTERY BEFORE REMOVING BATTERY OUTPUT WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO DO SO CAN RESULT IN INJURY OR DAMAGE TO ELECTRICAL SYSTEM. 1. Disconnect negative battery cable at battery. 2. Remove generator drive belt. 3. Unsnap plastic cable protector cover from B+ mounting stud. Fig. 3 Remove/Install Generator 4. In this engine: Remove 3 generator mounting bolts (Fig. 3). Position generator for access to wire connectors. Fig. 4 Generator Connectors - Typical Denso 5. Remove B+ terminal mounting nut at rear of generator (Fig. 4). Disconnect terminal from generator. 6. Disconnect field wire connector at rear of generator by pushing on connector tab and pulling connector from generator. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4822 7. Remove generator from vehicle. INSTALLATION 1. Position generator to engine and snap field wire connector into rear of generator. 2. Install B+ terminal to generator mounting stud. Tighten mounting nut to 12 Nm (108 in. lbs.) torque. 3. Install generator mounting fasteners and tighten as follows: - Vertical mounting bolt - 55 Nm (40 ft. lbs.). - Long horizontal mounting bolt - 55 Nm (40 ft. lbs.). - Short horizontal mounting bolt - 74 Nm (55 ft. lbs.). CAUTION: Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged. - When installing a serpentine accessory drive belt, the belt MUST be routed correctly. The water pump will be rotating in the wrong direction if the belt is installed incorrectly, causing the engine to overheat. 4. Install generator drive belt. 5. Snap cable protector cover to B+ mounting stud. 6. Install negative battery cable to battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Locations Voltage Regulator: Locations The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a voltage regulating circuit located within the Powertrain Control Module (PCM). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Locations > Page 4826 Voltage Regulator: Description and Operation The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a voltage regulating circuit located within the Powertrain Control Module (PCM). The EVR is not serviced separately. If replacement is necessary, the PCM must be replaced. The amount of DC current produced by the generator is controlled by EVR circuitry contained within the PCM. This circuitry is connected in series with the generators second rotor field terminal and its ground. Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field. The EVR circuitry monitors system line voltage (B+) and battery temperature (refer to Battery Temperature Sensor for more information). It then determines a target charging voltage. If sensed battery voltage is 0.5 volts or lower than the target voltage, the PCM grounds the field winding until sensed battery voltage is 0.5 volts above target voltage. A circuit in the PCM cycles the ground side of the generator field up to 100 times per second (100Hz), but has the capability to ground the field control wire 100% of the time (full field) to achieve the target voltage. If the charging rate cannot be monitored (limp-in), a duty cycle of 25% is used by the PCM in order to have some generator output. Also refer to Charging System Operation for additional information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications Starter Motor and Solenoid Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4831 Starter Motor: Description and Operation The starter motors used for this engine are not interchangeable with the starter motors used for the other available engines for this model. This engine starter motor is mounted with two bolts to the transmission housing on the left side of the engine. The electric motors of both starters have four brushes contacting the motor commutator. The starter motors use four electromagnetic field coils wound around four pole shoes. The starter motors are rated at 1.4 kilowatts (about 1.9 horsepower) output at 12 volts. The starter motors are serviced only as a unit with starter solenoids, and cannot be repaired. If either component is faulty or damaged, the entire starter motor and starter solenoid unit must be replaced. The starter motor is equipped with a gear reduction (intermediate transmission) system. The gear reduction system consists of a gear that is integral to the output end of the electric motor armature shaft that is in continual engagement with a larger gear that is splined to the input end of the starter pinion gear shaft. This feature makes it possible to reduce the dimensions of the starter. At the same time, it allows higher armature rotational speed, and delivers increased torque through the starter pinion gear to the starter ring gear. The starter motor is activated by an integral heavy duty starter solenoid switch mounted to the overrunning clutch housing. This electromechanical switch connects and disconnects the feed of battery voltage to the starter motor, and actuates a shift fork that engages and disengages the starter pinion gear with the starter ring gear. The starter motor uses an overrunning clutch and starter pinion gear unit to engage and drive the gears on the flywheel (or flywheel ring gear). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4832 Starter Motor: Testing and Inspection Correct starter motor operation can be confirmed by performing the following free running bench test. This test can only be performed with starter motor removed from vehicle. Refer to Specifications for starter motor specifications. 1. Remove starter motor from vehicle. Refer to Starter Motor Removal and Installation. 2. Mount starter motor securely in a soft-jawed bench vise. The vise jaws should be clamped on the mounting flange of starter motor. Never clamp on starter motor by field frame. 3. Connect a suitable volt-ampere tester and a 12-volt battery to starter motor in series, and set ammeter to 100 ampere scale. See instructions provided by manufacturer of volt-ampere tester being used. 4. Install jumper wire from solenoid terminal to solenoid battery terminal. The starter motor should operate. If starter motor fails to operate, replace faulty starter motor assembly. 5. Adjust carbon pile load of tester to obtain free running test voltage. Refer to in the Specifications for starter motor free running test voltage specifications. 6. Note reading on ammeter and compare reading to free running test maximum amperage draw. Refer to Specifications for starter motor free running test maximum amperage draw specifications. 7. If ammeter reading exceeds maximum amperage draw specification, replace faulty starter motor assembly. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4833 Starter Motor: Service and Repair REMOVAL With Manual Transmission 1. Disconnect and isolate negative battery cable. 2. Raise and support vehicle. Fig. 9 Starter Motor Remove/Install 3. Remove nut securing starter motor to stud on transmission housing (Fig. 9). 4. while supporting starter motor, remove bolt securing starter motor to transmission housing. 5. If equipped with automatic transmission, slide transmission cooler tube bracket forward on tubes far enough for starter motor to be removed from lower mounting stud. 6. Lower starter motor from front transmission housing far enough to access and remove nut securing battery cable eyelet to starter solenoid stud. Always support starter motor during this process. Do not let starter motor hang from wire harness. 7. Remove solenoid wire solenoid terminal stud. 8. Disconnect battery cable solenoid wire from receptacle on starter solenoid. 9. Remove starter motor from transmission housing. With Automatic Transmission 1. Disconnect and isolate negative battery cable. 2. Raise and support vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4834 Fig. 10 Starter Motor Remove/Install 3. Remove bolt and washer (rearward facing) securing starter motor to the transmission housing (Fig. 10). 4. while supporting starter motor, remove bolt and washer (rearward facing) securing starter motor to the transmission housing. 5. Lower starter motor from front of transmission housing far enough to access and remove nut securing battery positive cable eyelet terminal to the starter solenoid B(+) terminal stud. Always support starter motor during this process. Do not let starter motor hang from wire harness. 6. Remove battery cable eyelet terminal from solenoid B(+) terminal stud. 7. Disconnect battery cable solenoid terminal wire harness connector from receptacle on starter solenoid. 8. Remove starter motor from transmission housing. INSTALLATION With Manual Trans. 1. Position starter motor to transmission housing. 2. Connect battery cable solenoid terminal wire harness connector to connector receptacle on starter solenoid. Always support the starter motor during this process. Do not let the starter motor hang from the wire harness. 3. Install battery cable eyelet terminal onto solenoid B(+) terminal stud. 4. Install and tighten nut securing battery cable eyelet terminal to starter solenoid B(+) terminal stud. Tighten nut to 13.6 Nm (120 in. lbs.). 5. Position starter motor over stud on transmission housing. 6. If equipped with automatic transmission, slide automatic transmission cooler tube bracket rearward on tubes and into position over starter motor flange. 7. Loosely install the washers, bolt, and nut to starter. Tighten bolt and nut to 67.8 Nm (50 ft. lbs.). 8. Lower vehicle. 9. Connect negative battery cable. With Automatic Trans. 1. Position starter motor to transmission housing. 2. Connect battery cable solenoid terminal wire harness connector to connector receptacle on starter solenoid. Always support the starter motor during this process. Do not let the starter motor hang from the wire harness. 3. Install battery cable eyelet terminal onto solenoid B(+) terminal stud. 4. Install and tighten nut securing battery cable eyelet terminal to starter solenoid B(+) terminal stud. Tighten nut to 13.6 Nm (120 in. lbs.). 5. Position starter motor to transmission housing and loosely install two bolts/washers. 6. Tighten bolts to 67.8 Nm (50 ft. lbs.). 7. Lower vehicle. 8. Connect negative battery cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations Power Distribution Center Starter Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4838 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4839 Starter Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4840 Engine Starter Motor Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4841 Starter Relay: Description and Operation The starter relay is an electromechanical device that switches battery current to the pull-in coil of the starter solenoid when ignition switch is turned to Start position. The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. See PDC cover for relay identification and location. The starter relay is a International Standards Organization (ISO) relay. Relays conforming to ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The starter relay cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When electromagnetic coil is energized, it draws the movable contact away from normally closed fixed contact, and holds it against the other (normally open) fixed contact. When electromagnetic coil is de-energized, spring pressure returns movable contact to normally closed position. The resistor or diode is connected in parallel with electromagnetic coil within relay, and helps to dissipate voltage spikes produced when coil is de-energized. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4842 Starter Relay: Testing and Inspection Fig. 11 Starter Relay The starter relay (Fig. 11) is located in Power Distribution Center (PDC). Refer to PDC cover for relay identification and location. 1. Remove starter relay from PDC. 2. A relay in de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace faulty relay. 4. Connect 12V battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, perform Relay Circuit Test that follows. If not OK, replace faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair open circuit to fuse in PDC as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to common feed terminal (30) in the energized position. This terminal supplies battery voltage to starter solenoid field coils. There should be continuity between cavity for relay terminal 87 and starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair open circuit to starter solenoid as required. 4. The coil battery terminal (86) is connected to electromagnet in relay. It is energized when ignition switch is held in Start position. On vehicles with manual transmission, clutch pedal must be fully depressed for this test. Check for battery voltage at cavity for relay terminal 86 with ignition switch in Start position, and no voltage when ignition switch is released to ON position. If OK, go to Step 5. If not OK with automatic transmission, check for open or short circuit to ignition switch and repair, if required. If circuit to ignition switch is OK, refer to Ignition Switch and Key Lock Cylinder. If not OK with a manual transmission, check circuit between relay and clutch pedal position switch for open or a short. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. On vehicles with manual transmission, it is grounded at all times. On vehicles with automatic transmission, it is grounded through park/neutral position switch only when gearshift selector lever is in Park or Neutral positions. Check for continuity to ground at cavity for relay terminal 85. If not OK with manual transmission, repair circuit to ground as required. If not OK with automatic transmission, check for pen or short circuit to park/neutral position switch and repair, if required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4843 Starter Relay: Service and Repair REMOVAL 1. Disconnect and isolate negative battery cable. Fig. 12 Power Distribution Center 2. Remove cover from Power Distribution Center (PDC) (Fig. 12). 3. See fuse and relay layout label affixed to underside of PDC cover for starter relay identification and location. 4. Remove starter relay from PDC. INSTALLATION 1. See fuse and relay layout label affixed to underside of PDC cover for proper starter relay location. 2. Position starter relay in proper receptacle in PDC. 3. Align starter relay terminals with terminal cavities in PDC receptacle. 4. Push down firmly on starter relay until terminals are fully seated in terminal cavities in PDC receptacle. 5. Install cover onto PDC. 6. Reconnect negative battery cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications Starter Motor and Solenoid Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications > Page 4847 Starter Solenoid: Testing and Inspection This test can only be performed with starter motor removed from vehicle. 1. Remove starter motor from vehicle. Refer to Starter Motor Removal and Installation. 2. Disconnect wire from solenoid field coil terminal. Fig. 7 Continuity Test Between Solenoid Terminal And Field Coil Terminal - Typical 3. Check for continuity between solenoid terminal and solenoid field coil terminal with a continuity tester (Fig. 7). There should be continuity. If OK, go to Step 4. If not OK, replace faulty starter motor assembly. Fig. 8 Continuity Test Between Solenoid Terminal And Solenoid Case - Typical 4. Check for continuity between solenoid terminal and solenoid case (Fig. 8). There should be continuity. If not OK, replace faulty starter motor assembly. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations Auxiliary Power Outlet: Locations The cigar lighter is installed in the instrument panel lower bezel, which is located near the center of the instrument panel, below the radio. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4854 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4855 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4856 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4857 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4858 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4859 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4860 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4861 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4862 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4863 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4864 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4865 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4866 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4867 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4868 Auxiliary Power Outlet: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4869 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4870 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4871 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4872 Auxiliary Power Outlet: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4873 Auxiliary Power Outlet: Description and Operation Fig. 1 Cigar Lighter And Power Outlet CIGAR LIGHTER OUTLET A cigar lighter is standard equipment on this model. The cigar lighter is installed in the instrument panel lower bezel, which is located near the center of the instrument panel, below the radio. The cigar lighter base is secured by a snap fit within the instrument panel lower bezel. The cigar lighter knob and heating element unit and the cigar lighter receptacle unit are available for service. These components cannot be repaired and, if faulty or damaged, they must be replaced. The cigar lighter consists of two major components a knob and heating element unit, and the cigar lighter base or receptacle shell. The receptacle shell is connected to ground, and an insulated contact ii] the bottom of the shell is connected to battery current. The cigar lighter receives battery voltage from a fuse in the junction block only when the ignition switch is in the Accessory or ON positions. The knob and heating element are encased within a spring-loaded housing, which also features a sliding protective heat shield. When the knob and heating element are inserted in the receptacle shell, the heating element resistor coil is grounded through its housing to the receptacle shell. If the cigar lighter knob is pushed inward, the heat shield slides up toward the knob exposing the heating element, and the heating element extends from the housing toward the insulated contact in the bottom of the receptacle shell. Two small spring-clip retainers are located on either side of the insulated contact inside the bottom of the receptacle shell. These clips engage and hold the heating element against the insulated contact long enough for the resistor coil to heat up. When the heating element is engaged with the contact, battery current can flow through the resistor coil to ground, causing the resistor coil to heat. When the resistor coil becomes sufficiently heated, excess heat radiates from the heating element causing the spring-clips to expand. Once the spring-clips expand far enough to release the heating element, the spring-loaded housing forces the knob and heating element to pop back outward to their relaxed position. When the cigar lighter knob and element are pulled out of the receptacle shell, the protective heat shield slides downward on the housing so that the heating element is recessed and shielded around its circumference for safety. POWER OUTLET An accessory power outlet is optional equipment on this model. The power outlet is installed in the instrument panel lower bezel, which is located near the center of the instrument panel, below the radio. The power outlet base is secured by a snap fit within the instrument panel lower bezel. A plastic protective cap snaps into the power outlet base when the power outlet is not being used, and hangs from the power outlet base mount by an integral bail strap while the power outlet is in use. The power outlet receptacle unit and the accessory power outlet protective cap are available for service. The power outlet receptacle cannot be repaired and, if faulty or damaged, it must be replaced. The power outlet base or receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The power outlet receives battery voltage from a fuse in the Power Distribution Center (PDC) at all times. While the power outlet is very similar to a cigar lighter base unit, it does not include the two small spring-clip retainers inside the bottom of the receptacle shell that are used to secure the cigar lighter heating element to the insulated contact. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Cigar Lighter Outlet Test Auxiliary Power Outlet: Testing and Inspection Cigar Lighter Outlet Test WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fused ignition switch output (run/accessory) fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run/accessory) fuse in the junction block. If OK, go to Step 3. If not OK, repair the open fused ignition switch output (run/accessory) circuit to the ignition switch as required. 3. Turn the ignition switch to the OFF position. Remove the cigar lighter knob and element from the cigar lighter receptacle. Check for continuity between the inside circumference of the cigar lighter receptacle and a good ground. There should be continuity. If OK, go to Step 4. If not OK, go to Step 5. 4. Turn the ignition switch to the ON position. Check for battery voltage at the insulated contact located at the back of the cigar lighter receptacle. If OK, replace the faulty cigar lighter knob and element. If not OK, go to Step 5. 5. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Remove the instrument panel lower bezel. Check for continuity between the ground circuit cavity of the cigar lighter wire harness connector and a good ground. There should be continuity. If OK, go to Step 6. If not OK, repair the open ground circuit to ground as required. 6. Connect the battery negative cable. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run/accessory) circuit cavity of the cigar lighter wire harness connector. If OK, replace the faulty cigar lighter receptacle. If not OK, repair the open fused ignition switch output (run/accessory) circuit to the junction block fuse as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Cigar Lighter Outlet Test > Page 4876 Auxiliary Power Outlet: Testing and Inspection Power Outlet Test For complete circuit diagrams, refer to Power Outlet in the Component Index of Wiring Diagrams. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fused B(+) fuse in the Power Distribution Center (PDC). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fused B(+) fuse in the PDC. If OK, go to Step 3. If not OK, repair the open fused B(+) circuit to the battery as required. 3. Remove the plastic protective cap from the power outlet receptacle. Check for continuity between the inside circumference of the power outlet receptacle and a good ground. There should be continuity. If OK, go to Step 4. If not OK, go to Step 5. 4. Check for battery voltage at the insulated contact located at the back of the power outlet receptacle. If not OK, go to Step 5. 5. Disconnect and isolate the battery negative cable. Remove the instrument panel lower bezel. Check for continuity between the ground circuit cavity of the power outlet wire harness connector and a good ground. There should be continuity. If OK, go to Step 6. If not OK, repair the open ground circuit to ground as required. 6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the power outlet wire harness connector. If OK, replace the faulty power outlet receptacle. If not OK, repair the open fused B(+) circuit to the PDC fuse as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Cigar Lighter Outlet Replacement Auxiliary Power Outlet: Service and Repair Cigar Lighter Outlet Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Open the liftgate and remove the left rear cup holder assembly from the D-pillar trim. This will allow you to access the back side of the rear power outlet. Fig. 2 Cigar Lighter And Power Outlet Remove/Install - Typical 3. Look inside the power outlet receptacle base and note the position of the rectangular retaining bosses that secures the receptacle base to the D-pillar trim (Fig. 2). 4. Insert a pair of external snap ring pliers into the power outlet receptacle base and engage the tips of the pliers with the retaining bosses of the mount. 5. Squeeze the pliers to disengage the mount retaining bosses from the receptacle base and, using a gentle rocking motion, pull the pliers and the receptacle base out of the mount. It may also help to reach through to the back side of the power outlet and apply some force to help work the base out. 6. Remove the power outlet mount from the D-pillar trim. INSTALLATION 1. Install the power outlet mount into the D-pillar trim. 2. Align the splines on the outside of the cigar lighter or power outlet receptacle base connector receptacle with the grooves on the inside of the mount. 3. Press firmly on the cigar lighter or power outlet receptacle base until the retaining bosses of the mount are fully engaged in their receptacles. 4. Install the protective cap into the power outlet receptacle base. 5. Install the cup holder in the D-pillar trim panel. 6. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Cigar Lighter Outlet Replacement > Page 4879 Auxiliary Power Outlet: Service and Repair Power Outlet REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Open the liftgate and remove the left rear cup holder assembly from the D-pillar trim. This will allow you to access the back side of the rear power outlet. Fig. 9 Cigar Lighter And Power Outlet Remove/Install - Typical 3. Look inside the power outlet receptacle base and note the position of the rectangular retaining bosses that secures the receptacle base to the D-pillar trim (Fig. 9). 4. Insert a pair of external snap ring pliers into the power outlet receptacle base and engage the tips of the pliers with the retaining bosses of the mount. 5. Squeeze the pliers to disengage the mount retaining bosses from the receptacle base and, using a gentle rocking motion, pull the pliers and the receptacle base out of the mount. It may also help to reach through to the back side of the power outlet and apply some force to help work the base out. 6. Remove the power outlet mount from the D-pillar trim. INSTALLATION 1. Install the power outlet mount into the D-pillar trim. 2. Align the splines on the outside of the cigar lighter or power outlet receptacle base connector receptacle with the grooves on the inside of the mount. 3. Press firmly on the cigar lighter or power outlet receptacle base until the retaining bosses of the mount are fully engaged in their receptacles. 4. Install the protective cap into the power outlet receptacle base. 5. Install the cup holder in the D-pillar trim panel. 6. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Cigar Lighter Outlet Replacement > Page 4880 Auxiliary Power Outlet: Service and Repair Rear Power Outlet REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Open the liftgate and remove the left rear cup holder assembly from the D-pillar trim. This will allow you to access the back side of the rear power outlet. Fig. 12 Cigar Lighter And Power Outlet Remove/Install - Typical 3. Look inside the power outlet receptacle base and note the position of the rectangular retaining bosses that secures the receptacle base to the D-pillar trim (Fig. 12). 4. Insert a pair of external snap ring pliers into the power outlet receptacle base and engage the tips of the pliers with the retaining bosses of the mount. 5. Squeeze the pliers to disengage the mount retaining bosses from the receptacle base and, using a gentle rocking motion, pull the pliers and the receptacle base out of the mount. It may also help to reach through to the back side of the power outlet and apply some force to help work the base out. 6. Remove the power outlet mount from the D-pillar trim. INSTALLATION 1. Install the power outlet mount into the D-pillar trim. 2. Align the splines on the outside of the cigar lighter or power outlet receptacle base connector receptacle with the grooves on the inside of the mount. 3. Press firmly on the cigar lighter or power outlet receptacle base until the retaining bosses of the mount are fully engaged in their receptacles. 4. Install the protective cap into the power outlet receptacle base. 5. Install the cup holder in the D-pillar trim panel. 6. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions Circuit Breaker: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4885 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4886 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4887 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4888 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4889 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4890 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4891 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4892 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4893 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4894 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4895 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4896 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4897 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4898 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4899 Circuit Breaker: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4900 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4901 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4902 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4903 Circuit Breaker: Electrical Diagrams 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4904 8w-12-3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4905 8w-12-5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Page 4906 Circuit Breaker: Description and Operation An automatic resetting circuit breaker in the junction block is used to protect the power seat system circuit. The circuit breaker can protect the system from a short circuit, or from an overload condition caused by an obstructed or stuck seat adjuster. The circuit breaker cannot be repaired and, if faulty or damaged, it must be replaced. An automatic resetting circuit breaker in the junction block is used to protect the power window system circuit. The circuit breaker can protect the system from a short circuit, or from an overload condition caused by an obstructed or stuck window glass or regulator. The circuit breaker cannot be repaired and, if faulty, it must be replaced. 1. Locate the correct circuit breaker in the junction block. Pull out the circuit breaker slightly, but be certain that the circuit breaker terminals still contact the terminals in the junction block cavities. 2. Connect the negative lead of a 12-volt DC voltmeter to a good ground. 3. With the voltmeter positive lead, check both terminals of the circuit breaker for battery voltage. If only one terminal has battery voltage, the circuit breaker is faulty and must be replaced. If neither terminal has battery voltage, repair the open circuit from the Power Distribution Center (PDC) as required. 1. Locate the circuit breaker in the junction block. Pull out the circuit breaker slightly, but be certain that the circuit breaker terminals still contact the terminals in the junction block cavities. 2. Connect the negative lead of a 12-volt DC voltmeter to a good ground. 3. With the voltmeter positive lead, check both terminals of the circuit breaker for battery voltage. If only one terminal has battery voltage, the circuit breaker is faulty and must be replaced. If neither terminal has battery voltage, repair the open circuit from the Power Distribution Center (PDC) as required. If the circuit breaker checks OK, but no power windows operate, see Power Window System in the Diagnosis and Testing. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Locations Power Distribution Center (PDC): Locations The molded plastic PDC housing is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 8w-10-8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 4912 Power Distribution Center (PDC): Diagrams C107 C107 C107 (in PDC) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 4913 8w-10-9 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 4914 Power Distribution Center (PDC): Diagrams Joint Connector 1 Joint Connector No. 1 (in PDC) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 4915 8w-10-10 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 4916 Power Distribution Center (PDC): Diagrams Joint Connector 2 Joint Connector No. 2 (in PDC) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 4917 8w-10-11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 4918 Power Distribution Center (PDC): Diagrams 8w-10-8 C107 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 4919 C107 (in PDC) 8w-10-9 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 4920 Joint Connector No. 1 (in PDC) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 4921 8w-10-10 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 4922 Joint Connector No. 2 (in PDC) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 4923 8w-10-11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 4924 Joint Connector No. 3 (in PDC) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 4925 8w-10-12 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 4926 Joint Connector No. 4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Page 4927 Power Distribution Center (PDC): Description and Operation POWER DISTRIBUTION This covers the various standard and optional power distribution components used on this model. The power distribution system for this vehicle consists of the following components: Power Distribution Center (PDC) - Junction Block (JB) - Relay and Fuse Block. The power distribution system also incorporates various types of circuit control and protection features, including: Automatic resetting circuit breakers - Blade-type fuses - Cartridge fuses - Circuit splice blocks - Flashers - Relays. Following are general descriptions of the major components in the power distribution system. See the owner's manual in the vehicle glove box for more information on the features and use of all of the power distribution system components. The power distribution system for this vehicle is designed to provide safe, reliable, and centralized distribution points for the electrical current required to operate all of the many standard and optional factory-installed electrical and electronic powertrain, chassis, safety, security, comfort and convenience systems. At the same time, the power distribution system was designed to provide ready access to these electrical distribution points for the vehicle technician to use when conducting diagnosis and repair of faulty circuits. The power distribution system can also prove useful for the sourcing of additional electrical circuits that may be required to provide the electrical current needed to operate many accessories that the vehicle owner may choose to have installed in the aftermarket. Fig. 1 Cigar Lighter And Power Outlet CIGAR LIGHTER OUTLET A cigar lighter is standard equipment on this model. The cigar lighter is installed in the instrument panel lower bezel, which is located near the center of the instrument panel, below the radio. The cigar lighter base is secured by a snap fit within the instrument panel lower bezel. The cigar lighter knob and heating element unit and the cigar lighter receptacle unit are available for service. These components cannot be repaired and, if faulty or damaged, they must be replaced. The cigar lighter consists of two major components a knob and heating element unit, and the cigar lighter base or receptacle shell. The receptacle shell is connected to ground, and an insulated contact ii] the bottom of the shell is connected to battery current. The cigar lighter receives battery voltage from a fuse in the junction block only when the ignition switch is in the Accessory or ON positions. The knob and heating element are encased within a spring-loaded housing, which also features a sliding protective heat shield. When the knob and heating element are inserted in the receptacle shell, the heating element resistor coil is grounded through its housing to the receptacle shell. If the cigar lighter knob is pushed inward, the heat shield slides up toward the knob exposing the heating element, and the heating element extends from the housing toward the insulated contact in the bottom of the receptacle shell. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Page 4928 Two small spring-clip retainers are located on either side of the insulated contact inside the bottom of the receptacle shell. These clips engage and hold the heating element against the insulated contact long enough for the resistor coil to heat up. When the heating element is engaged with the contact, battery current can flow through the resistor coil to ground, causing the resistor coil to heat. When the resistor coil becomes sufficiently heated, excess heat radiates from the heating element causing the spring-clips to expand. Once the spring-clips expand far enough to release the heating element, the spring-loaded housing forces the knob and heating element to pop back outward to their relaxed position. When the cigar lighter knob and element are pulled out of the receptacle shell, the protective heat shield slides downward on the housing so that the heating element is recessed and shielded around its circumference for safety. CIRCUIT BREAKER An automatic resetting circuit breaker in the junction block is used to protect the power seat system circuit. The circuit breaker can protect the system from a short circuit, or from an overload condition caused by an obstructed or stuck seat adjuster. The circuit breaker cannot be repaired and, if faulty or damaged, it must be replaced. An automatic resetting circuit breaker in the junction block is used to protect the power window system circuit. The circuit breaker can protect the system from a short circuit, or from an overload condition caused by an obstructed or stuck window glass or regulator. The circuit breaker cannot be repaired and, if faulty, it must be replaced. Circuit Breaker 1. Locate the correct circuit breaker in the junction block. Pull out the circuit breaker slightly, but be certain that the circuit breaker terminals still contact the terminals in the junction block cavities. 2. Connect the negative lead of a 12-volt DC voltmeter to a good ground. 3. With the voltmeter positive lead, check both terminals of the circuit breaker for battery voltage. If only one terminal has battery voltage, the circuit breaker is faulty and must be replaced. If neither terminal has battery voltage, repair the open circuit from the Power Distribution Center (PDC) as required. Circuit Breaker 1. Locate the circuit breaker in the junction block. Pull out the circuit breaker slightly, but be certain that the circuit breaker terminals still contact the terminals in the junction block cavities. 2. Connect the negative lead of a 12-volt DC voltmeter to a good ground. 3. With the voltmeter positive lead, check both terminals of the circuit breaker for battery voltage. If only one terminal has battery voltage, the circuit breaker is faulty and must be replaced. If neither terminal has battery voltage, repair the open circuit from the Power Distribution Center (PDC) as required. If the circuit breaker checks OK, but no power windows operate, see Power Window System in the Diagnosis and Testing. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Page 4929 Fig. 3 Ignition-Off Draw Fuse - Typical IOD FUSE All vehicles are equipped with an Ignition-Off Draw (IOD) fuse (Fig. 3) that is disconnected within the Junction Block (JB) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the JB as part of the preparation procedures performed just prior to new vehicle delivery. The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed to provide service access to the fuses in the JB. A finger recess is molded into the access panel for easy removal. An adhesive-backed fuse layout map is secured to the instrument panel side of the access panel to ensure proper fuse identification. The IOD fuse is a 15 ampere mini blade-type fuse. The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in its JB cavity, and as a fuse holder that conveniently stores the fuse in the same JB cavity after it has been disconnected. The term ignition-off draw identifies a normal condition where power is being drained from the battery with the ignition switch in the OFF position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the OFF position, including the clock. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from JB fuse cavity 12 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse serves no useful purpose to the dealer technician in the service or diagnosis of any vehicle system or condition, other than the same purpose as that of any other standard circuit protection device. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Refer to Battery for the location of additional service information covering the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Page 4930 Fig. 5 Junction Block Location JUNCTION BLOCK An electrical Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover (Fig. 5). The JB serves to simplify and centralize numerous electrical components, and to distribute electrical current to many of the accessory systems in the vehicle. It also eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. The JB houses up to nineteen blade-type fuses (two standard-type and seventeen mini-type), up to two blade- type automatic resetting circuit breakers, and two International Standards Organization (ISO) relays (one standard-type and one micro-type). The molded plastic JB housing has integral mounting brackets that are secured with two screws to the left instrument panel end bracket. The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed for service of the JB. A fuse puller and spare fuse holders are located on the back of the fuse access cover, as well as an adhesive- backed fuse layout map to ensure proper fuse identification. The JB unit cannot be repaired and is only serviced as an assembly. If any internal circuit or the JB housing is faulty or damaged, the entire JB unit must be replaced. All of the circuits entering and leaving the JB do so through up to nine wire harness connectors, which are connected to the JB through integral connector receptacles molded into the JB housing. Internal connection of all of the JB circuits is accomplished by an intricate combination of hard wiring and bus bars. Refer to Junction Block for the location of complete JB circuit diagrams. Fig. 8 Power Distribution Center Location - Typical Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Page 4931 POWER DISTRIBUTION CENTER All of the electrical current distributed throughout this vehicle is directed through the standard equipment Power Distribution Center (PDC) (Fig. 8). The molded plastic PDC housing is located in the left front corner of the engine compartment, just behind the battery. The PDC houses the generator cartridge fuse and up to ten maxi-type cartridge fuses, which replace all in-line fusible links. The PDC also houses up to seven blade-type mini fuses, up to thirteen International Standards Organization (ISO) relays (one standard-type and twelve micro-type), two joint connectors (one sixteen-way and one twenty-six-way) and a sixteen-way engine wire harness in-line connector. The PDC housing is secured in the engine compartment at three points. Integral mounts on the front and inboard sides of the PDC housing engage and latch to stanchions that are integral to the molded plastic battery tray. An integral bracket on the rear of the PDC housing is secured with a screw to the top of the left front inner wheel house. The PDC housing has a molded plastic cover that includes two integral latches, one on each side. The PDC cover is easily opened and removed for service access and has a convenient fuse and relay layout map integral to the inside surface of the cover to ensure proper component identification. The PDC unit cannot be repaired and is only serviced as a unit with the headlamp and dash wire harness. If the internal circuits or the PDC housing are faulty or damaged, the headlamp and dash wire harness unit must be replaced. All of the current from the battery and the generator output enters the PDC through one cable with eyelets that are secured with a nut to the one B(+) terminal stud located just inside the inboard side of the PDC housing. The PDC cover is unlatched and removed to access the battery and generator output connection B(+) terminal studs, the fuses, the relays, the joint connectors and the engine wire harness inline connector. Internal connection of all of the PDC circuits is accomplished by an intricate combination of hard wiring and bus bars. POWER OUTLET An accessory power outlet is optional equipment on this model. The power outlet is installed in the instrument panel lower bezel, which is located near the center of the instrument panel, below the radio. The power outlet base is secured by a snap fit within the instrument panel lower bezel. A plastic protective cap snaps into the power outlet base when the power outlet is not being used, and hangs from the power outlet base mount by an integral bail strap while the power outlet is in use. The power outlet receptacle unit and the accessory power outlet protective cap are available for service. The power outlet receptacle cannot be repaired and, if faulty or damaged, it must be replaced. The power outlet base or receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The power outlet receives battery voltage from a fuse in the Power Distribution Center (PDC) at all times. While the power outlet is very similar to a cigar lighter base unit, it does not include the two small spring-clip retainers inside the bottom of the receptacle shell that are used to secure the cigar lighter heating element to the insulated contact. Fig. 10 Relay And Fuse Block Location RELAY CENTER The relay and fuse block is snap fit onto mounting tabs located on the end of the Junction Block (JB) nearest to the dash panel, under the left outboard end of the instrument panel (Fig. 10). The relay and fuse block provides additional capacity for distribution and control of electrical current for some of the accessory systems that are unique to this vehicle, and which could not be accommodated by the JB or the Power Distribution Center (PDC). The relay and fuse block has cavities for up to four additional blade4ype mini fuses, the electronic combination flasher, and three additional International Standards Organization relays (one standard-type and two micro-type). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Page 4932 The relay and fuse block components are accessed for service by removing the steering column opening cover from the instrument panel. The relay and fuse block is then disengaged from the JB mounting tabs and pulled out from under the instrument panel. Service replacement of the relay and fuse block unit requires instrument panel assembly removal. The relay and fuse block unit cannot be repaired and is only serviced as a unit with the instrument panel wire harness assembly. If the relay and fuse block housing or its internal circuits are faulty or damaged, the entire instrument panel wire harness unit must be replaced. The relay and fuse block is integral to the instrument panel wire harness, and all circuits entering or leaving this module do so through the instrument panel wire harness. Internal connection of all of the relay and fuse block circuits is accomplished by hard wiring. Refer to Fuse/Fuse Block for the location of complete circuit diagrams and cavity assignments for the relay and fuse block. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Page 4933 Power Distribution Center (PDC): Service and Repair REMOVAL The Power Distribution Center (PDC) is serviced as a unit with the headlamp and dash wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and headlamp and dash wire harness unit must be replaced. 1. Disconnect and isolate the battery negative cable. 2. Disconnect each of the headlamp and dash wire harness connectors. Refer to Connector Locations in the Wiring for the location of more information on the headlamp and dash wire harness connector locations. 3. Remove all of the fasteners that secure each of the headlamp and dash wire harness ground eyelets to the vehicle body and chassis components. Refer to Connector Locations for the location of more information on the ground eyelet locations. 4. Disengage each of the retainers that secure the headlamp and dash wire harness to the vehicle body and chassis components. Refer to Connector Locations for the location of more information on the headlamp and dash wire harness retainer locations. 5. Unlatch and remove the cover from the PDC. 6. Disconnect the engine wire harness in-line connector from the PDC connector receptacle. 7. Slide the engine wire harness retainer clip upward and disengage the harness from the trough on the rear of the PDC housing. 8. Remove the nut that secures the eyelet of the battery negative cable generator output take out to the rearward B(+) terminal stud in the PDC and remove the eyelet from the stud. 9. Remove the nut that secures the eyelet of the battery positive cable PDC take out to the B(+) terminal stud in the PDC and remove the eyelet from the stud. 10. Remove the screw that secures the PDC housing to the left front fender wheel housing. 11. Disengage the latches for the two PDC mounts and lift the unit OFF of the battery tray stanchions. 12. Remove the PDC and the headlamp and dash wire harness from the engine compartment as a unit. INSTALLATION The Power Distribution Center (PDC) is serviced as a unit with the headlamp and dash wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and headlamp and dash wire harness unit must be replaced. NOTE: If the PDC is being replaced with a new unit, be certain to transfer each of the blade-type fuses, cartridge fuses and relays from the faulty PDC to the proper cavities of the replacement PDC. Refer to Power Distribution for the location of complete PDC circuit diagrams and cavity assignments. 1. Position the PDC and the headlamp and dash wire harness unit in the engine compartment. 2. Install the two PDC mounts onto the two stanchions of the battery tray. 3. Install and tighten the screw that secures the PDC housing to the left front fender wheel housing. Tighten the screw to 7.9 Nm (70 in. lbs.). 4. Install the eyelet of the battery positive cable PDC take out onto the forward B(+) terminal stud in the PDC. 5. Install and tighten the nut that secures the eyelet of the battery positive cable PDC take out to the forward B(+) terminal stud in the PDC. Tighten the nut to 9 Nm (80 in. lbs.). 6. Install the eyelet of the battery negative cable generator output take out onto the rearward B(+) terminal stud in the PDC. 7. Install and tighten the nut that secures the eyelet of the battery negative cable generator output take out to the rearward B(+) terminal stud in the PDC. Tighten the nut to 9 Nm (80 in. lbs.). 8. Engage the engine wire harness in the trough on the back of the PDC housing and secure it with the retainer clip. 9. Reconnect the engine wire harness in-line connector to the PDC in-line connector receptacle. 10. Install and latch the cover onto the PDC. 11. Engage each of the retainers that secure the headlamp and dash wire harness to the vehicle body and chassis components. Refer to Connector Locations for the location of more information on the headlamp and dash wire harness retainer locations. 12. Install all of the fasteners that secure each of the headlamp and dash wire harness ground eyelets to the vehicle body and chassis components. Refer to Connector Locations for the location of more information on the ground eyelet locations. 13. Reconnect each of the headlamp and dash wire harness connectors. Refer to Connector Locations for the location of more information on the headlamp and dash wire harness connector locations. 14. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Junction Block Fuse: Locations Junction Block Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Junction Block > Page 4938 Fuse: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block Fuse: Diagrams Junction Block 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4941 8w-12-3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4942 8w-12-4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4943 8w-12-5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4944 Junction Block C1 Junction Block C2 Junction Block C3 Junction Block C4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4945 Junction Block C5 Junction Block C6 Junction Block C7 Junction Block C8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4946 Junction Block C9 Junction Block C10 Junction Block C11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4947 Junction Block C12 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4948 Fuse: Diagrams Power Distribution Center 8w-10-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4949 8w-10-3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4950 8w-10-4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4951 8w-10-5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4952 8w-10-6 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4953 8w-10-7 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4954 8w-10-8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4955 8w-10-9 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4956 8w-10-10 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4957 8w-10-11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4958 8w-10-12 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Junction Block Fuse: Application and ID Junction Block Junction Block Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Junction Block > Page 4961 Fuse: Application and ID Power Distribution Center Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Junction Block Fuse Block: Locations Junction Block Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Junction Block > Page 4966 Fuse Block: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4969 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4970 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4971 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4972 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4973 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4974 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4975 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4976 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4977 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4978 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4979 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4980 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4981 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4982 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4983 Fuse Block: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4984 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4985 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4986 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4987 Fuse Block: Connector Views Junction Block 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4988 8w-12-3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4989 8w-12-4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4990 8w-12-5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4991 Junction Block C1 Junction Block C2 Junction Block C3 Junction Block C4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4992 Junction Block C5 Junction Block C6 Junction Block C7 Junction Block C8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4993 Junction Block C9 Junction Block C10 Junction Block C11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4994 Junction Block C12 Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4995 8w-10-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4996 8w-10-3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4997 8w-10-4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4998 8w-10-5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4999 8w-10-6 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5000 8w-10-7 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5001 8w-10-8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5002 8w-10-9 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5003 8w-10-10 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5004 8w-10-11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5005 8w-10-12 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5006 Fuse Block: Electrical Diagrams 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5007 8w-12-3 Wiring Diagrams Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5008 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5009 8w-12-6 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5010 8w-12-7 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5011 8w-12-8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5012 8w-12-9 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5013 8w-12-10 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5014 8w-12-11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5015 8w-12-12 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5016 8w-12-13 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5017 8w-12-14 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5018 8w-12-15 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5019 8w-12-16 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5020 8w-12-17 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5021 8w-12-18 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5022 8w-12-19 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5023 8w-12-20 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5024 8w-12-21 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5025 8w-12-22 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams See: Diagrams/Electrical Diagrams Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 5026 Fuse Block: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Junction Block Fuse Block: Application and ID Junction Block Junction Block Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Junction Block > Page 5029 Fuse Block: Application and ID Power Distribution Center Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Page 5030 Fuse Block: Description and Operation Fig. 5 Junction Block Location An electrical Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover (Fig. 5). The JB serves to simplify and centralize numerous electrical components, and to distribute electrical current to many of the accessory systems in the vehicle. It also eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. The JB houses up to nineteen blade-type fuses (two standard-type and seventeen mini-type), up to two blade- type automatic resetting circuit breakers, and two International Standards Organization (ISO) relays (one standard-type and one micro-type). The molded plastic JB housing has integral mounting brackets that are secured with two screws to the left instrument panel end bracket. The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed for service of the JB. A fuse puller and spare fuse holders are located on the back of the fuse access cover, as well as an adhesive-backed fuse layout map to ensure proper fuse identification. The JB unit cannot be repaired and is only serviced as an assembly. If any internal circuit or the JB housing is faulty or damaged, the entire JB unit must be replaced. All of the circuits entering and leaving the JB do so through up to nine wire harness connectors, which are connected to the JB through integral connector receptacles molded into the JB housing. Internal connection of all of the JB circuits is accomplished by an intricate combination of hard wiring and bus bars. Refer to Junction Block for the location of complete JB circuit diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Page 5031 Fuse Block: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Fig. 6 Fuse Access Panel Remove/Install 2. Remove the fuse access panel by unsnapping it from the left outboard end of the instrument panel (Fig. 6). 3. Reach through the instrument panel fuse access panel opening to access and remove the one screw that secures the Junction Block (JB) to the left instrument panel end bracket. 4. Remove the steering column opening cover from the instrument panel. Refer to Steering Column Opening Cover for the location of the steering column opening cover removal procedures. Fig. 7 Junction Block Remove/Install 5. Reach through the outboard side of the instrument panel steering column opening to access and disconnect all of the wire harness connectors from the JB connector receptacles (Fig. 7). 6. Reach through the outboard side of the instrument panel steering column opening to access and remove the relay and fuse block from the JB. Push Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Page 5032 the relay and fuse block towards the left end of the instrument panel to disengage its mounting slots from the tabs on the JB. 7. Reach through the outboard side of the instrument panel steering column opening to access and remove the one screw that secures the JB to the left instrument panel end bracket. 8. Reach through the outboard side of the instrument panel steering column opening to remove the JB from the left instrument panel end bracket. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: If the Junction Block (JB) is being replaced with a new unit, be certain to transfer each of the fuses, circuit breakers and relays from the faulty JB to the proper cavities of the replacement JB. Refer to Junction Block for the location of complete circuit diagrams and cavity assignments for the JB. 1. Reach through the outboard side of the instrument panel steering column opening to position the JB onto the left instrument panel end bracket. 2. Reach through the outboard side of the instrument panel steering column opening to install and tighten the one screw that secures the JB to the left instrument panel end bracket. Tighten the screw to 2.2 Nm (20 in. lbs.). 3. Reach through the outboard side of the instrument panel steering column opening to access and install the relay and fuse block onto the JB by engaging the relay and fuse block mounting slots with the tabs on the JB. 4. Reach through the outboard side of the instrument panel steering column opening to access and reconnect all of the wire harness connectors to the JB connector receptacles. 5. Install the steering column opening cover onto the instrument panel. Refer to Steering Column Opening Cover for the location of the steering column opening cover installation procedures. 6. Reach through the instrument panel fuse access panel opening to install and tighten the one screw that secures the junction block to the left instrument panel end bracket. Tighten the screw to 2.2 Nm (20 in. lbs.). 7. Install the fuse access panel by snapping it onto the left outboard end of the instrument panel. 8. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Recalls for Multiple Junction Connector: > F42 > Oct > 06 > Recall Potential Interior Fire Technical Service Bulletin # F42 Date: 061001 Recall - Potential Interior Fire October 2006 Dealer Service Instructions for: Safety Recall F42 Unused Wiring Connector Models 2001-2003 (DN) Dodge Durango NOTE: This recall applies only to the above vehicles equipped with a 40/20/40 bench seat (sales code CBE). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject An unused wiring connector under the front seat on about 34,900 of the above vehicles may become contaminated with spilled fluid and/or debris. This may cause a short circuit, which can result in an interior fire. Repair The unused connector under the front seat must be inspected for corrosion/debris and cleaned as necessary. In addition, a connector seal with a plastic retainer clip must be installed on the unused connector. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Recalls for Multiple Junction Connector: > F42 > Oct > 06 > Recall Potential Interior Fire > Page 5041 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Recalls for Multiple Junction Connector: > F42 > Oct > 06 > Recall Potential Interior Fire > Page 5042 Use the labor operation number and time allowance shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure 1. Open the driver's door and move the driver's seat to the full rearward position. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Recalls for Multiple Junction Connector: > F42 > Oct > 06 > Recall Potential Interior Fire > Page 5043 2. Locate the unused electrical connector under the driver's seat near the transmission tunnel (Figure 1). NOTE: If the male side of the unused connector is missing, order male connector CBDPF422 for 2001 model year vehicles or CBDPF423 for 2002/2003 model year vehicles. 3. Slide the red locking tab towards the driver's side of the vehicle to release the primary lock on the connector. 4. Squeeze the tail end of the male connector to release the secondary connector lock and pull the connector apart. 5. Inspect the wiring harness side of the connector for corrosion and/or debris. If corrosion and/or debris is found, use Electrolyte Detection and Neutralizing Spray (P/N CBEJD201) to clean the corrosion and/or debris from the connector. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Recalls for Multiple Junction Connector: > F42 > Oct > 06 > Recall Potential Interior Fire > Page 5044 6. Install the connector end seal, retainer cap and cavity plugs into the empty male connector (removed in Step 4) as shown in Figure 2. 7. Install the male connector onto the unused wiring harness connector and engage the red lock tab by sliding the lock tab towards the passenger side of the vehicle (Figure 2). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Recalls for Multiple Junction Connector: > F42 > Oct > 06 > Recall Potential Interior Fire > Page 5045 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Recalls for Multiple Junction Connector: > NHTSA06V339000 > Sep > 06 > Recall 06V339000: Console Wiring Connector Modification Multiple Junction Connector: Recalls Recall 06V339000: Console Wiring Connector Modification MAKE/MODELS: MODEL/BUILD YEARS: Dodge/Durango 2001-2003 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 06V339000 MFG'S REPORT DATE: September 06, 2006 COMPONENT: Electrical System POTENTIAL NUMBER OF UNITS AFFECTED: 35103 SUMMARY: On certain sport utility vehicles equipped with front bench seats only, if fluid is spilled from the floor mounted cup holder, an unused console power outlet connector located under the seat may become contaminated. CONSEQUENCE: This may allow development of a high resistive short circuit in the connector, which could eventually lead to a fire. REMEDY: Dealers will inspect the console wiring connector for corrosion, clean as required, and install a cap to prevent additional fluid from contaminating the connector free of charge. The manufacturer has not yet provided an owner notification schedule. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. F42. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > F42 > Oct > 06 > Recall - Potential Interior Fire Technical Service Bulletin # F42 Date: 061001 Recall - Potential Interior Fire October 2006 Dealer Service Instructions for: Safety Recall F42 Unused Wiring Connector Models 2001-2003 (DN) Dodge Durango NOTE: This recall applies only to the above vehicles equipped with a 40/20/40 bench seat (sales code CBE). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject An unused wiring connector under the front seat on about 34,900 of the above vehicles may become contaminated with spilled fluid and/or debris. This may cause a short circuit, which can result in an interior fire. Repair The unused connector under the front seat must be inspected for corrosion/debris and cleaned as necessary. In addition, a connector seal with a plastic retainer clip must be installed on the unused connector. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > F42 > Oct > 06 > Recall - Potential Interior Fire > Page 5055 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > F42 > Oct > 06 > Recall - Potential Interior Fire > Page 5056 Use the labor operation number and time allowance shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure 1. Open the driver's door and move the driver's seat to the full rearward position. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > F42 > Oct > 06 > Recall - Potential Interior Fire > Page 5057 2. Locate the unused electrical connector under the driver's seat near the transmission tunnel (Figure 1). NOTE: If the male side of the unused connector is missing, order male connector CBDPF422 for 2001 model year vehicles or CBDPF423 for 2002/2003 model year vehicles. 3. Slide the red locking tab towards the driver's side of the vehicle to release the primary lock on the connector. 4. Squeeze the tail end of the male connector to release the secondary connector lock and pull the connector apart. 5. Inspect the wiring harness side of the connector for corrosion and/or debris. If corrosion and/or debris is found, use Electrolyte Detection and Neutralizing Spray (P/N CBEJD201) to clean the corrosion and/or debris from the connector. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > F42 > Oct > 06 > Recall - Potential Interior Fire > Page 5058 6. Install the connector end seal, retainer cap and cavity plugs into the empty male connector (removed in Step 4) as shown in Figure 2. 7. Install the male connector onto the unused wiring harness connector and engage the red lock tab by sliding the lock tab towards the passenger side of the vehicle (Figure 2). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > F42 > Oct > 06 > Recall - Potential Interior Fire > Page 5059 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > NHTSA06V339000 > Sep > 06 > Recall 06V339000: Console Wiring Connector Modification Multiple Junction Connector: All Technical Service Bulletins Recall 06V339000: Console Wiring Connector Modification MAKE/MODELS: MODEL/BUILD YEARS: Dodge/Durango 2001-2003 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 06V339000 MFG'S REPORT DATE: September 06, 2006 COMPONENT: Electrical System POTENTIAL NUMBER OF UNITS AFFECTED: 35103 SUMMARY: On certain sport utility vehicles equipped with front bench seats only, if fluid is spilled from the floor mounted cup holder, an unused console power outlet connector located under the seat may become contaminated. CONSEQUENCE: This may allow development of a high resistive short circuit in the connector, which could eventually lead to a fire. REMEDY: Dealers will inspect the console wiring connector for corrosion, clean as required, and install a cap to prevent additional fluid from contaminating the connector free of charge. The manufacturer has not yet provided an owner notification schedule. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. F42. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Joint Connector No. 1 and No. 2 Multiple Junction Connector: Diagrams Joint Connector No. 1 and No. 2 Joint Connector No.1 (In PDC) Joint Connector No.2 (In PDC) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Joint Connector No. 1 and No. 2 > Page 5066 Multiple Junction Connector: Diagrams Joint Connector No. 3 and No. 4 Joint Connector No.3 (In PDC) Joint Connector No.4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Locations Ignition Off-Draw (IOD) Fuse: Locations The IOD fuse is located in the junction block. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Locations > Page 5070 Ignition Off-Draw (IOD) Fuse: Description and Operation IGNITION-OFF DRAW FUSE All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is removed when the vehicle is shipped from the factory. This fuse feeds various accessories that require battery current when the ignition switch is in the OFF position, including the clock. The IOD fuse is removed to prevent battery discharge during vehicle storage. When removing or installing the IOD fuse, it is important that the ignition switch be in the OFF position. Failure to place the ignition switch in the OFF position can cause the radio display to become scram- bled when the IOD fuse is removed and replaced. Removing and replacing the IOD fuse again, with the ignition switch in the OFF position, will correct the scrambled display condition. The IOD fuse should be checked if the radio or clock displays are inoperative. The IOD fuse is located in the junction block. Refer to the fuse layout label on the back of the instrument panel fuse access panel for IOD fuse identification and location. Fig. 3 Ignition-Off Draw Fuse - Typical IOD FUSE All vehicles are equipped with an Ignition-Off Draw (IOD) fuse (Fig. 3) that is disconnected within the Junction Block (JB) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the JB as part of the preparation procedures performed just prior to new vehicle delivery. The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed to provide service access to the fuses in the JB. A finger recess is molded into the access panel for easy removal. An adhesive-backed fuse layout map is secured to the instrument panel side of the access panel to ensure proper fuse identification. The IOD fuse is a 15 ampere mini blade-type fuse. The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in its JB cavity, and as a fuse holder that conveniently stores the fuse in the same JB cavity after it has been disconnected. The term ignition-off draw identifies a normal condition where power is being drained from the battery with the ignition switch in the OFF position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the OFF position, including the clock. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from JB fuse cavity 12 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse serves no useful purpose to the dealer technician in the service or diagnosis of any vehicle system or condition, other than the same purpose as that of any other standard circuit protection device. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Locations > Page 5071 The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Refer to Battery for the location of additional service information covering the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Locations > Page 5072 Ignition Off-Draw (IOD) Fuse: Testing and Inspection Ignition-Off Draw Test The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the OFF position. A normal vehicle electrical system will draw from five to thirty-five milliamperes (0.005 to 0.035 ampere) with the ignition switch in the OFF position, and all non-ignition controlled circuits in proper working order. Up to thirty-five milliamperes are needed to enable the memory functions for the Powertrain Control Module (PCM), digital clock, electronically tuned radio, and other modules which may vary with the vehicle equipment. A vehicle that has not been operated for approximately twenty days, may discharge the battery to an inadequate level. When a vehicle will not be used for twenty days or more (stored), remove the IOD fuse from the Power Distribution Center (PDC). This will reduce battery discharging. Excessive IOD can be caused by: - Electrical items left ON. - Faulty or improperly adjusted switches. - Faulty or shorted electronic modules and components. - An internally shorted generator. - Intermittent shorts in the wiring. If the IOD is over thirty-five milliamperes, the problem must be found and corrected before replacing a battery. In most cases, the battery can be charged and returned to service after the excessive IOD condition has been corrected. Electronic Module Ignition-Off-Draw (IOD) Table 1. Verify that all electrical accessories are OFF. Turn OFF all lamps, remove the ignition key, and close all doors. If the vehicle is equipped with an illuminated entry system or an electronically tuned radio, allow the electronic timer function of these systems to automatically shut off (time out). This may take up to three minutes. See the Electronic Module Ignition-Off Draw Table for more information. 2. Determine that the underhood lamp is operating properly, then disconnect the lamp wire harness connector or remove the lamp bulb. 3. Disconnect the battery negative cable. 4. Set an electronic digital multi-meter to its highest amperage scale. Connect the multi-meter between the disconnected battery negative cable terminal clamp and the battery negative terminal post. Make sure that the doors remain closed so that the illuminated entry system is not activated. The multi-meter amperage reading may remain high for up to three minutes, or may not give any reading at all while set in the highest amperage scale, depending upon the electrical equipment in the vehicle. The multi-meter leads must be securely clamped to the battery negative cable terminal clamp and the battery negative terminal post. If continuity between the battery negative terminal post and the negative cable terminal clamp is lost during any part of the IOD test, the electronic timer function will be activated and all of the tests will have to be repeated. 5. After about three minutes, the high-amperage IOD reading on the multi-meter should become very low or nonexistent, depending upon the electrical equipment in the vehicle. If the amperage reading remains high, remove and replace each fuse or circuit breaker in the Power Distribution Center (PDC) and then in the Junction Block (JB), one at a time until the amperage reading becomes very low, or nonexistent. This will isolate each circuit and identify the circuit that is the source of the high-amperage IOD. If the amperage reading remains high after removing and replacing each fuse and circuit breaker, disconnect the wire harness from the generator. If the amperage reading now becomes very low or nonexistent, refer to Charging System for the proper charging system diagnosis and testing procedures. After the high-amperage IOD has been corrected, switch the multi-meter to progressively lower amperage scales and, if necessary, repeat the fuse and circuit breaker remove-and-replace process to identify and correct all sources of excessive IOD. It is now safe to select the lowest milliampere scale of the multi-meter to check the low- amperage IOD. CAUTION: Do not open any doors, or turn ON any electrical accessories with the lowest milliampere scale selected, or the multi-meter may be Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Locations > Page 5073 damaged. 6. Observe the multi-meter reading. The low-amperage IOD should not exceed thirty-five milliamperes (0.035 ampere). If the current draw exceeds thirty-five milliamperes, isolate each circuit using the fuse and circuit breaker remove-and-replace process in Step 5. The multi-meter reading will drop to within the acceptable limit when the source of the excessive current draw is disconnected. Repair this circuit as required; whether a wiring short, incorrect switch adjustment, or a component failure is at fault. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Locations > Page 5074 Ignition Off-Draw (IOD) Fuse: Service and Repair Fig. 4 Ignition-Off Draw Fuse - Typical REMOVAL The Ignition-Off Draw (IOD) fuse is disconnected from Junction Block (JB) fuse cavity 12 (Fig. 4) when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. NOTE: When removing or installing the IOD fuse, it is important that the ignition switch be in the OFF position. Failure to place the ignition switch in the OFF position can cause the radio display to become scrambled when the IOD fuse is installed. Removing and installing the IOD fuse again with the ignition switch in the Oft position will usually correct the scrambled radio display condition. 1. Turn the ignition switch to the OFF position. 2. Remove the fuse access panel by unsnapping it from the left outboard end of the instrument panel. 3. Grasp the upper and lower tabs of the IOD fuse holder unit in fuse cavity 12 of the JB between the thumb and forefinger and pull the unit firmly outward. 4. Install the fuse access panel by snapping it onto the left outboard end of the instrument panel. INSTALLATION The Ignition-Off Draw (IOD) fuse is disconnected from Junction Block (JB) fuse cavity 12 (Fig. 4) when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. 1. Turn the ignition switch to the OFF position. 2. Remove the fuse access panel by unsnapping it from the left outboard end of the instrument panel. 3. To install the IOD fuse, use a thumb to press the IOD fuse holder unit in fuse cavity 12 firmly into the JB. 4. Install the fuse access panel by snapping it onto the left outboard end of the instrument panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block Relay Box: Locations Junction Block Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block > Page 5080 Relay Box: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block Relay Box: Diagrams Junction Block 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5083 8w-12-3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5084 8w-12-4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5085 8w-12-5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5086 Junction Block C1 Junction Block C2 Junction Block C3 Junction Block C4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5087 Junction Block C5 Junction Block C6 Junction Block C7 Junction Block C8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5088 Junction Block C9 Junction Block C10 Junction Block C11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5089 Junction Block C12 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5090 Relay Box: Diagrams Power Distribution Center 8w-10-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5091 8w-10-3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5092 8w-10-4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5093 8w-10-5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5094 8w-10-6 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5095 8w-10-7 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5096 8w-10-8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5097 8w-10-9 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5098 8w-10-10 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5099 8w-10-11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5100 8w-10-12 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Page 5101 Relay Box: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block Relay Box: Application and ID Junction Block Junction Block Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 5104 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 5105 Relay Box: Application and ID Power Distribution Center Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 5106 Relay Box: Description and Operation Fig. 10 Relay And Fuse Block Location RELAY CENTER The relay and fuse block is snap fit onto mounting tabs located on the end of the Junction Block (JB) nearest to the dash panel, under the left outboard end of the instrument panel (Fig. 10). The relay and fuse block provides additional capacity for distribution and control of electrical current for some of the accessory systems that are unique to this vehicle, and which could not be accommodated by the JB or the Power Distribution Center (PDC). The relay and fuse block has cavities for up to four additional blade4ype mini fuses, the electronic combination flasher, and three additional International Standards Organization relays (one standard-type and two micro-type). The relay and fuse block components are accessed for service by removing the steering column opening cover from the instrument panel. The relay and fuse block is then disengaged from the JB mounting tabs and pulled out from under the instrument panel. Service replacement of the relay and fuse block unit requires instrument panel assembly removal. The relay and fuse block unit cannot be repaired and is only serviced as a unit with the instrument panel wire harness assembly. If the relay and fuse block housing or its internal circuits are faulty or damaged, the entire instrument panel wire harness unit must be replaced. The relay and fuse block is integral to the instrument panel wire harness, and all circuits entering or leaving this module do so through the instrument panel wire harness. Internal connection of all of the relay and fuse block circuits is accomplished by hard wiring. Refer to Fuse/Fuse Block for the location of complete circuit diagrams and cavity assignments for the relay and fuse block. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 5107 Relay Box: Service and Repair REMOVAL The relay and fuse block is serviced as a unit with the instrument panel wire harness. If any internal circuit of the relay and fuse block or the relay and fuse block housing is faulty or damaged, the entire instrument panel wire harness unit must be replaced. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel assembly from the dash panel. Refer to Instrument Panel Assembly for the instrument panel assembly removal procedures. 3. Disconnect each of the instrument panel wire harness connectors. Refer to Connector Locations for the location of more information on the instrument panel wire harness connector locations. 4. Remove all of the fasteners that secure each of the instrument panel wire harness ground eyelets to the instrument panel components. Refer to Connector Locations for the location of more information on the ground eyelet locations. 5. Disengage each of the retainers that secure the instrument panel wire harness to the instrument panel components. Refer to Connector Locations for the location of more information on the instrument panel wire harness retainer locations. Fig. 11 Relay And Fuse Block Remove/Install 6. Push the relay and fuse block towards the left end of the instrument panel to disengage its mounting slots from the tabs on the Junction Block (JB) (Fig. 11). 7. Remove the relay and fuse block and the instrument panel wire harness from the instrument panel as a unit. INSTALLATION The relay and fuse block is serviced as a unit with the instrument panel wire harness. If any internal circuit of the relay and fuse block or the relay and fuse block housing is faulty or damaged, the entire instrument panel wire harness unit must be replaced. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: If the relay and fuse block is being replaced with a new unit, be certain to transfer each of the fuses, the flasher and the relays from the faulty relay and fuse block to the proper cavities of the replacement relay and fuse block. Refer to Fuse' Fuse Block for the location of complete relay and fuse block circuit diagrams and cavity assignments. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 5108 1. Position the relay and fuse block and the instrument panel wire harness onto the instrument panel. 2. Install the relay and fuse block by engaging its mounting slots onto the tabs on the Junction Block (JB). 3. Engage each of the retainers that secure the instrument panel wire harness to the instrument panel components. Refer to Connector Locations for the location of more information on the instrument panel wire harness retainer locations. 4. Install all of the fasteners that secure each of the instrument panel wire harness ground eyelets to the instrument panel components. Refer to Connector Locations for the location of more information on the ground eyelet locations. 5. Reconnect each of the instrument panel wire harness connectors. Refer to Connector Locations for the location of more information on the instrument panel wire harness connector locations. 6. Install the instrument panel assembly onto the dash panel. Refer to Instrument Panel Assembly for the location of the instrument panel assembly installation procedures. 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block Relay Box: Locations Junction Block Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block > Page 5113 Relay Box: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block Relay Box: Diagrams Junction Block 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5116 8w-12-3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5117 8w-12-4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5118 8w-12-5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5119 Junction Block C1 Junction Block C2 Junction Block C3 Junction Block C4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5120 Junction Block C5 Junction Block C6 Junction Block C7 Junction Block C8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5121 Junction Block C9 Junction Block C10 Junction Block C11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5122 Junction Block C12 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5123 Relay Box: Diagrams Power Distribution Center 8w-10-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5124 8w-10-3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5125 8w-10-4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5126 8w-10-5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5127 8w-10-6 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5128 8w-10-7 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5129 8w-10-8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5130 8w-10-9 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5131 8w-10-10 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5132 8w-10-11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5133 8w-10-12 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Page 5134 Relay Box: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block Relay Box: Application and ID Junction Block Junction Block Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 5137 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 5138 Relay Box: Application and ID Power Distribution Center Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 5139 Relay Box: Description and Operation Fig. 10 Relay And Fuse Block Location RELAY CENTER The relay and fuse block is snap fit onto mounting tabs located on the end of the Junction Block (JB) nearest to the dash panel, under the left outboard end of the instrument panel (Fig. 10). The relay and fuse block provides additional capacity for distribution and control of electrical current for some of the accessory systems that are unique to this vehicle, and which could not be accommodated by the JB or the Power Distribution Center (PDC). The relay and fuse block has cavities for up to four additional blade4ype mini fuses, the electronic combination flasher, and three additional International Standards Organization relays (one standard-type and two micro-type). The relay and fuse block components are accessed for service by removing the steering column opening cover from the instrument panel. The relay and fuse block is then disengaged from the JB mounting tabs and pulled out from under the instrument panel. Service replacement of the relay and fuse block unit requires instrument panel assembly removal. The relay and fuse block unit cannot be repaired and is only serviced as a unit with the instrument panel wire harness assembly. If the relay and fuse block housing or its internal circuits are faulty or damaged, the entire instrument panel wire harness unit must be replaced. The relay and fuse block is integral to the instrument panel wire harness, and all circuits entering or leaving this module do so through the instrument panel wire harness. Internal connection of all of the relay and fuse block circuits is accomplished by hard wiring. Refer to Fuse/Fuse Block for the location of complete circuit diagrams and cavity assignments for the relay and fuse block. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 5140 Relay Box: Service and Repair REMOVAL The relay and fuse block is serviced as a unit with the instrument panel wire harness. If any internal circuit of the relay and fuse block or the relay and fuse block housing is faulty or damaged, the entire instrument panel wire harness unit must be replaced. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel assembly from the dash panel. Refer to Instrument Panel Assembly for the instrument panel assembly removal procedures. 3. Disconnect each of the instrument panel wire harness connectors. Refer to Connector Locations for the location of more information on the instrument panel wire harness connector locations. 4. Remove all of the fasteners that secure each of the instrument panel wire harness ground eyelets to the instrument panel components. Refer to Connector Locations for the location of more information on the ground eyelet locations. 5. Disengage each of the retainers that secure the instrument panel wire harness to the instrument panel components. Refer to Connector Locations for the location of more information on the instrument panel wire harness retainer locations. Fig. 11 Relay And Fuse Block Remove/Install 6. Push the relay and fuse block towards the left end of the instrument panel to disengage its mounting slots from the tabs on the Junction Block (JB) (Fig. 11). 7. Remove the relay and fuse block and the instrument panel wire harness from the instrument panel as a unit. INSTALLATION The relay and fuse block is serviced as a unit with the instrument panel wire harness. If any internal circuit of the relay and fuse block or the relay and fuse block housing is faulty or damaged, the entire instrument panel wire harness unit must be replaced. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: If the relay and fuse block is being replaced with a new unit, be certain to transfer each of the fuses, the flasher and the relays from the faulty relay and fuse block to the proper cavities of the replacement relay and fuse block. Refer to Fuse' Fuse Block for the location of complete relay and fuse block circuit diagrams and cavity assignments. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 5141 1. Position the relay and fuse block and the instrument panel wire harness onto the instrument panel. 2. Install the relay and fuse block by engaging its mounting slots onto the tabs on the Junction Block (JB). 3. Engage each of the retainers that secure the instrument panel wire harness to the instrument panel components. Refer to Connector Locations for the location of more information on the instrument panel wire harness retainer locations. 4. Install all of the fasteners that secure each of the instrument panel wire harness ground eyelets to the instrument panel components. Refer to Connector Locations for the location of more information on the ground eyelet locations. 5. Reconnect each of the instrument panel wire harness connectors. Refer to Connector Locations for the location of more information on the instrument panel wire harness connector locations. 6. Install the instrument panel assembly onto the dash panel. Refer to Instrument Panel Assembly for the location of the instrument panel assembly installation procedures. 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Locations Ignition Off-Draw (IOD) Fuse: Locations The IOD fuse is located in the junction block. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Locations > Page 5146 Ignition Off-Draw (IOD) Fuse: Description and Operation IGNITION-OFF DRAW FUSE All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is removed when the vehicle is shipped from the factory. This fuse feeds various accessories that require battery current when the ignition switch is in the OFF position, including the clock. The IOD fuse is removed to prevent battery discharge during vehicle storage. When removing or installing the IOD fuse, it is important that the ignition switch be in the OFF position. Failure to place the ignition switch in the OFF position can cause the radio display to become scram- bled when the IOD fuse is removed and replaced. Removing and replacing the IOD fuse again, with the ignition switch in the OFF position, will correct the scrambled display condition. The IOD fuse should be checked if the radio or clock displays are inoperative. The IOD fuse is located in the junction block. Refer to the fuse layout label on the back of the instrument panel fuse access panel for IOD fuse identification and location. Fig. 3 Ignition-Off Draw Fuse - Typical IOD FUSE All vehicles are equipped with an Ignition-Off Draw (IOD) fuse (Fig. 3) that is disconnected within the Junction Block (JB) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the JB as part of the preparation procedures performed just prior to new vehicle delivery. The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed to provide service access to the fuses in the JB. A finger recess is molded into the access panel for easy removal. An adhesive-backed fuse layout map is secured to the instrument panel side of the access panel to ensure proper fuse identification. The IOD fuse is a 15 ampere mini blade-type fuse. The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in its JB cavity, and as a fuse holder that conveniently stores the fuse in the same JB cavity after it has been disconnected. The term ignition-off draw identifies a normal condition where power is being drained from the battery with the ignition switch in the OFF position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the OFF position, including the clock. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from JB fuse cavity 12 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse serves no useful purpose to the dealer technician in the service or diagnosis of any vehicle system or condition, other than the same purpose as that of any other standard circuit protection device. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Locations > Page 5147 The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Refer to Battery for the location of additional service information covering the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Locations > Page 5148 Ignition Off-Draw (IOD) Fuse: Testing and Inspection Ignition-Off Draw Test The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the OFF position. A normal vehicle electrical system will draw from five to thirty-five milliamperes (0.005 to 0.035 ampere) with the ignition switch in the OFF position, and all non-ignition controlled circuits in proper working order. Up to thirty-five milliamperes are needed to enable the memory functions for the Powertrain Control Module (PCM), digital clock, electronically tuned radio, and other modules which may vary with the vehicle equipment. A vehicle that has not been operated for approximately twenty days, may discharge the battery to an inadequate level. When a vehicle will not be used for twenty days or more (stored), remove the IOD fuse from the Power Distribution Center (PDC). This will reduce battery discharging. Excessive IOD can be caused by: - Electrical items left ON. - Faulty or improperly adjusted switches. - Faulty or shorted electronic modules and components. - An internally shorted generator. - Intermittent shorts in the wiring. If the IOD is over thirty-five milliamperes, the problem must be found and corrected before replacing a battery. In most cases, the battery can be charged and returned to service after the excessive IOD condition has been corrected. Electronic Module Ignition-Off-Draw (IOD) Table 1. Verify that all electrical accessories are OFF. Turn OFF all lamps, remove the ignition key, and close all doors. If the vehicle is equipped with an illuminated entry system or an electronically tuned radio, allow the electronic timer function of these systems to automatically shut off (time out). This may take up to three minutes. See the Electronic Module Ignition-Off Draw Table for more information. 2. Determine that the underhood lamp is operating properly, then disconnect the lamp wire harness connector or remove the lamp bulb. 3. Disconnect the battery negative cable. 4. Set an electronic digital multi-meter to its highest amperage scale. Connect the multi-meter between the disconnected battery negative cable terminal clamp and the battery negative terminal post. Make sure that the doors remain closed so that the illuminated entry system is not activated. The multi-meter amperage reading may remain high for up to three minutes, or may not give any reading at all while set in the highest amperage scale, depending upon the electrical equipment in the vehicle. The multi-meter leads must be securely clamped to the battery negative cable terminal clamp and the battery negative terminal post. If continuity between the battery negative terminal post and the negative cable terminal clamp is lost during any part of the IOD test, the electronic timer function will be activated and all of the tests will have to be repeated. 5. After about three minutes, the high-amperage IOD reading on the multi-meter should become very low or nonexistent, depending upon the electrical equipment in the vehicle. If the amperage reading remains high, remove and replace each fuse or circuit breaker in the Power Distribution Center (PDC) and then in the Junction Block (JB), one at a time until the amperage reading becomes very low, or nonexistent. This will isolate each circuit and identify the circuit that is the source of the high-amperage IOD. If the amperage reading remains high after removing and replacing each fuse and circuit breaker, disconnect the wire harness from the generator. If the amperage reading now becomes very low or nonexistent, refer to Charging System for the proper charging system diagnosis and testing procedures. After the high-amperage IOD has been corrected, switch the multi-meter to progressively lower amperage scales and, if necessary, repeat the fuse and circuit breaker remove-and-replace process to identify and correct all sources of excessive IOD. It is now safe to select the lowest milliampere scale of the multi-meter to check the low- amperage IOD. CAUTION: Do not open any doors, or turn ON any electrical accessories with the lowest milliampere scale selected, or the multi-meter may be Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Locations > Page 5149 damaged. 6. Observe the multi-meter reading. The low-amperage IOD should not exceed thirty-five milliamperes (0.035 ampere). If the current draw exceeds thirty-five milliamperes, isolate each circuit using the fuse and circuit breaker remove-and-replace process in Step 5. The multi-meter reading will drop to within the acceptable limit when the source of the excessive current draw is disconnected. Repair this circuit as required; whether a wiring short, incorrect switch adjustment, or a component failure is at fault. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Locations > Page 5150 Ignition Off-Draw (IOD) Fuse: Service and Repair Fig. 4 Ignition-Off Draw Fuse - Typical REMOVAL The Ignition-Off Draw (IOD) fuse is disconnected from Junction Block (JB) fuse cavity 12 (Fig. 4) when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. NOTE: When removing or installing the IOD fuse, it is important that the ignition switch be in the OFF position. Failure to place the ignition switch in the OFF position can cause the radio display to become scrambled when the IOD fuse is installed. Removing and installing the IOD fuse again with the ignition switch in the Oft position will usually correct the scrambled radio display condition. 1. Turn the ignition switch to the OFF position. 2. Remove the fuse access panel by unsnapping it from the left outboard end of the instrument panel. 3. Grasp the upper and lower tabs of the IOD fuse holder unit in fuse cavity 12 of the JB between the thumb and forefinger and pull the unit firmly outward. 4. Install the fuse access panel by snapping it onto the left outboard end of the instrument panel. INSTALLATION The Ignition-Off Draw (IOD) fuse is disconnected from Junction Block (JB) fuse cavity 12 (Fig. 4) when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. 1. Turn the ignition switch to the OFF position. 2. Remove the fuse access panel by unsnapping it from the left outboard end of the instrument panel. 3. To install the IOD fuse, use a thumb to press the IOD fuse holder unit in fuse cavity 12 firmly into the JB. 4. Install the fuse access panel by snapping it onto the left outboard end of the instrument panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > F42 > Oct > 06 > Recall - Potential Interior Fire Technical Service Bulletin # F42 Date: 061001 Recall - Potential Interior Fire October 2006 Dealer Service Instructions for: Safety Recall F42 Unused Wiring Connector Models 2001-2003 (DN) Dodge Durango NOTE: This recall applies only to the above vehicles equipped with a 40/20/40 bench seat (sales code CBE). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject An unused wiring connector under the front seat on about 34,900 of the above vehicles may become contaminated with spilled fluid and/or debris. This may cause a short circuit, which can result in an interior fire. Repair The unused connector under the front seat must be inspected for corrosion/debris and cleaned as necessary. In addition, a connector seal with a plastic retainer clip must be installed on the unused connector. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > F42 > Oct > 06 > Recall - Potential Interior Fire > Page 5159 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > F42 > Oct > 06 > Recall - Potential Interior Fire > Page 5160 Use the labor operation number and time allowance shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure 1. Open the driver's door and move the driver's seat to the full rearward position. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > F42 > Oct > 06 > Recall - Potential Interior Fire > Page 5161 2. Locate the unused electrical connector under the driver's seat near the transmission tunnel (Figure 1). NOTE: If the male side of the unused connector is missing, order male connector CBDPF422 for 2001 model year vehicles or CBDPF423 for 2002/2003 model year vehicles. 3. Slide the red locking tab towards the driver's side of the vehicle to release the primary lock on the connector. 4. Squeeze the tail end of the male connector to release the secondary connector lock and pull the connector apart. 5. Inspect the wiring harness side of the connector for corrosion and/or debris. If corrosion and/or debris is found, use Electrolyte Detection and Neutralizing Spray (P/N CBEJD201) to clean the corrosion and/or debris from the connector. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > F42 > Oct > 06 > Recall - Potential Interior Fire > Page 5162 6. Install the connector end seal, retainer cap and cavity plugs into the empty male connector (removed in Step 4) as shown in Figure 2. 7. Install the male connector onto the unused wiring harness connector and engage the red lock tab by sliding the lock tab towards the passenger side of the vehicle (Figure 2). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > F42 > Oct > 06 > Recall - Potential Interior Fire > Page 5163 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > NHTSA06V339000 > Sep > 06 > Recall 06V339000: Console Wiring Connector Modification Wiring Harness: Recalls Recall 06V339000: Console Wiring Connector Modification MAKE/MODELS: MODEL/BUILD YEARS: Dodge/Durango 2001-2003 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 06V339000 MFG'S REPORT DATE: September 06, 2006 COMPONENT: Electrical System POTENTIAL NUMBER OF UNITS AFFECTED: 35103 SUMMARY: On certain sport utility vehicles equipped with front bench seats only, if fluid is spilled from the floor mounted cup holder, an unused console power outlet connector located under the seat may become contaminated. CONSEQUENCE: This may allow development of a high resistive short circuit in the connector, which could eventually lead to a fire. REMEDY: Dealers will inspect the console wiring connector for corrosion, clean as required, and install a cap to prevent additional fluid from contaminating the connector free of charge. The manufacturer has not yet provided an owner notification schedule. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. F42. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > F42 > Oct > 06 > Recall Potential Interior Fire Technical Service Bulletin # F42 Date: 061001 Recall - Potential Interior Fire October 2006 Dealer Service Instructions for: Safety Recall F42 Unused Wiring Connector Models 2001-2003 (DN) Dodge Durango NOTE: This recall applies only to the above vehicles equipped with a 40/20/40 bench seat (sales code CBE). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject An unused wiring connector under the front seat on about 34,900 of the above vehicles may become contaminated with spilled fluid and/or debris. This may cause a short circuit, which can result in an interior fire. Repair The unused connector under the front seat must be inspected for corrosion/debris and cleaned as necessary. In addition, a connector seal with a plastic retainer clip must be installed on the unused connector. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > F42 > Oct > 06 > Recall Potential Interior Fire > Page 5173 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > F42 > Oct > 06 > Recall Potential Interior Fire > Page 5174 Use the labor operation number and time allowance shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure 1. Open the driver's door and move the driver's seat to the full rearward position. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > F42 > Oct > 06 > Recall Potential Interior Fire > Page 5175 2. Locate the unused electrical connector under the driver's seat near the transmission tunnel (Figure 1). NOTE: If the male side of the unused connector is missing, order male connector CBDPF422 for 2001 model year vehicles or CBDPF423 for 2002/2003 model year vehicles. 3. Slide the red locking tab towards the driver's side of the vehicle to release the primary lock on the connector. 4. Squeeze the tail end of the male connector to release the secondary connector lock and pull the connector apart. 5. Inspect the wiring harness side of the connector for corrosion and/or debris. If corrosion and/or debris is found, use Electrolyte Detection and Neutralizing Spray (P/N CBEJD201) to clean the corrosion and/or debris from the connector. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > F42 > Oct > 06 > Recall Potential Interior Fire > Page 5176 6. Install the connector end seal, retainer cap and cavity plugs into the empty male connector (removed in Step 4) as shown in Figure 2. 7. Install the male connector onto the unused wiring harness connector and engage the red lock tab by sliding the lock tab towards the passenger side of the vehicle (Figure 2). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > F42 > Oct > 06 > Recall Potential Interior Fire > Page 5177 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > NHTSA06V339000 > Sep > 06 > Recall 06V339000: Console Wiring Connector Modification Wiring Harness: All Technical Service Bulletins Recall 06V339000: Console Wiring Connector Modification MAKE/MODELS: MODEL/BUILD YEARS: Dodge/Durango 2001-2003 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 06V339000 MFG'S REPORT DATE: September 06, 2006 COMPONENT: Electrical System POTENTIAL NUMBER OF UNITS AFFECTED: 35103 SUMMARY: On certain sport utility vehicles equipped with front bench seats only, if fluid is spilled from the floor mounted cup holder, an unused console power outlet connector located under the seat may become contaminated. CONSEQUENCE: This may allow development of a high resistive short circuit in the connector, which could eventually lead to a fire. REMEDY: Dealers will inspect the console wiring connector for corrosion, clean as required, and install a cap to prevent additional fluid from contaminating the connector free of charge. The manufacturer has not yet provided an owner notification schedule. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. F42. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations Auxiliary Power Outlet: Locations The cigar lighter is installed in the instrument panel lower bezel, which is located near the center of the instrument panel, below the radio. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5188 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5189 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5190 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5191 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5192 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5193 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5194 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5195 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5196 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5197 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5198 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5199 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5200 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5201 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5202 Auxiliary Power Outlet: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5203 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5204 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5205 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 5206 Auxiliary Power Outlet: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 5207 Auxiliary Power Outlet: Description and Operation Fig. 1 Cigar Lighter And Power Outlet CIGAR LIGHTER OUTLET A cigar lighter is standard equipment on this model. The cigar lighter is installed in the instrument panel lower bezel, which is located near the center of the instrument panel, below the radio. The cigar lighter base is secured by a snap fit within the instrument panel lower bezel. The cigar lighter knob and heating element unit and the cigar lighter receptacle unit are available for service. These components cannot be repaired and, if faulty or damaged, they must be replaced. The cigar lighter consists of two major components a knob and heating element unit, and the cigar lighter base or receptacle shell. The receptacle shell is connected to ground, and an insulated contact ii] the bottom of the shell is connected to battery current. The cigar lighter receives battery voltage from a fuse in the junction block only when the ignition switch is in the Accessory or ON positions. The knob and heating element are encased within a spring-loaded housing, which also features a sliding protective heat shield. When the knob and heating element are inserted in the receptacle shell, the heating element resistor coil is grounded through its housing to the receptacle shell. If the cigar lighter knob is pushed inward, the heat shield slides up toward the knob exposing the heating element, and the heating element extends from the housing toward the insulated contact in the bottom of the receptacle shell. Two small spring-clip retainers are located on either side of the insulated contact inside the bottom of the receptacle shell. These clips engage and hold the heating element against the insulated contact long enough for the resistor coil to heat up. When the heating element is engaged with the contact, battery current can flow through the resistor coil to ground, causing the resistor coil to heat. When the resistor coil becomes sufficiently heated, excess heat radiates from the heating element causing the spring-clips to expand. Once the spring-clips expand far enough to release the heating element, the spring-loaded housing forces the knob and heating element to pop back outward to their relaxed position. When the cigar lighter knob and element are pulled out of the receptacle shell, the protective heat shield slides downward on the housing so that the heating element is recessed and shielded around its circumference for safety. POWER OUTLET An accessory power outlet is optional equipment on this model. The power outlet is installed in the instrument panel lower bezel, which is located near the center of the instrument panel, below the radio. The power outlet base is secured by a snap fit within the instrument panel lower bezel. A plastic protective cap snaps into the power outlet base when the power outlet is not being used, and hangs from the power outlet base mount by an integral bail strap while the power outlet is in use. The power outlet receptacle unit and the accessory power outlet protective cap are available for service. The power outlet receptacle cannot be repaired and, if faulty or damaged, it must be replaced. The power outlet base or receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The power outlet receives battery voltage from a fuse in the Power Distribution Center (PDC) at all times. While the power outlet is very similar to a cigar lighter base unit, it does not include the two small spring-clip retainers inside the bottom of the receptacle shell that are used to secure the cigar lighter heating element to the insulated contact. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Cigar Lighter Outlet Test Auxiliary Power Outlet: Testing and Inspection Cigar Lighter Outlet Test WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fused ignition switch output (run/accessory) fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run/accessory) fuse in the junction block. If OK, go to Step 3. If not OK, repair the open fused ignition switch output (run/accessory) circuit to the ignition switch as required. 3. Turn the ignition switch to the OFF position. Remove the cigar lighter knob and element from the cigar lighter receptacle. Check for continuity between the inside circumference of the cigar lighter receptacle and a good ground. There should be continuity. If OK, go to Step 4. If not OK, go to Step 5. 4. Turn the ignition switch to the ON position. Check for battery voltage at the insulated contact located at the back of the cigar lighter receptacle. If OK, replace the faulty cigar lighter knob and element. If not OK, go to Step 5. 5. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Remove the instrument panel lower bezel. Check for continuity between the ground circuit cavity of the cigar lighter wire harness connector and a good ground. There should be continuity. If OK, go to Step 6. If not OK, repair the open ground circuit to ground as required. 6. Connect the battery negative cable. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run/accessory) circuit cavity of the cigar lighter wire harness connector. If OK, replace the faulty cigar lighter receptacle. If not OK, repair the open fused ignition switch output (run/accessory) circuit to the junction block fuse as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Cigar Lighter Outlet Test > Page 5210 Auxiliary Power Outlet: Testing and Inspection Power Outlet Test For complete circuit diagrams, refer to Power Outlet in the Component Index of Wiring Diagrams. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fused B(+) fuse in the Power Distribution Center (PDC). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fused B(+) fuse in the PDC. If OK, go to Step 3. If not OK, repair the open fused B(+) circuit to the battery as required. 3. Remove the plastic protective cap from the power outlet receptacle. Check for continuity between the inside circumference of the power outlet receptacle and a good ground. There should be continuity. If OK, go to Step 4. If not OK, go to Step 5. 4. Check for battery voltage at the insulated contact located at the back of the power outlet receptacle. If not OK, go to Step 5. 5. Disconnect and isolate the battery negative cable. Remove the instrument panel lower bezel. Check for continuity between the ground circuit cavity of the power outlet wire harness connector and a good ground. There should be continuity. If OK, go to Step 6. If not OK, repair the open ground circuit to ground as required. 6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the power outlet wire harness connector. If OK, replace the faulty power outlet receptacle. If not OK, repair the open fused B(+) circuit to the PDC fuse as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Cigar Lighter Outlet Replacement Auxiliary Power Outlet: Service and Repair Cigar Lighter Outlet Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Open the liftgate and remove the left rear cup holder assembly from the D-pillar trim. This will allow you to access the back side of the rear power outlet. Fig. 2 Cigar Lighter And Power Outlet Remove/Install - Typical 3. Look inside the power outlet receptacle base and note the position of the rectangular retaining bosses that secures the receptacle base to the D-pillar trim (Fig. 2). 4. Insert a pair of external snap ring pliers into the power outlet receptacle base and engage the tips of the pliers with the retaining bosses of the mount. 5. Squeeze the pliers to disengage the mount retaining bosses from the receptacle base and, using a gentle rocking motion, pull the pliers and the receptacle base out of the mount. It may also help to reach through to the back side of the power outlet and apply some force to help work the base out. 6. Remove the power outlet mount from the D-pillar trim. INSTALLATION 1. Install the power outlet mount into the D-pillar trim. 2. Align the splines on the outside of the cigar lighter or power outlet receptacle base connector receptacle with the grooves on the inside of the mount. 3. Press firmly on the cigar lighter or power outlet receptacle base until the retaining bosses of the mount are fully engaged in their receptacles. 4. Install the protective cap into the power outlet receptacle base. 5. Install the cup holder in the D-pillar trim panel. 6. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Cigar Lighter Outlet Replacement > Page 5213 Auxiliary Power Outlet: Service and Repair Power Outlet REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Open the liftgate and remove the left rear cup holder assembly from the D-pillar trim. This will allow you to access the back side of the rear power outlet. Fig. 9 Cigar Lighter And Power Outlet Remove/Install - Typical 3. Look inside the power outlet receptacle base and note the position of the rectangular retaining bosses that secures the receptacle base to the D-pillar trim (Fig. 9). 4. Insert a pair of external snap ring pliers into the power outlet receptacle base and engage the tips of the pliers with the retaining bosses of the mount. 5. Squeeze the pliers to disengage the mount retaining bosses from the receptacle base and, using a gentle rocking motion, pull the pliers and the receptacle base out of the mount. It may also help to reach through to the back side of the power outlet and apply some force to help work the base out. 6. Remove the power outlet mount from the D-pillar trim. INSTALLATION 1. Install the power outlet mount into the D-pillar trim. 2. Align the splines on the outside of the cigar lighter or power outlet receptacle base connector receptacle with the grooves on the inside of the mount. 3. Press firmly on the cigar lighter or power outlet receptacle base until the retaining bosses of the mount are fully engaged in their receptacles. 4. Install the protective cap into the power outlet receptacle base. 5. Install the cup holder in the D-pillar trim panel. 6. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Cigar Lighter Outlet Replacement > Page 5214 Auxiliary Power Outlet: Service and Repair Rear Power Outlet REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Open the liftgate and remove the left rear cup holder assembly from the D-pillar trim. This will allow you to access the back side of the rear power outlet. Fig. 12 Cigar Lighter And Power Outlet Remove/Install - Typical 3. Look inside the power outlet receptacle base and note the position of the rectangular retaining bosses that secures the receptacle base to the D-pillar trim (Fig. 12). 4. Insert a pair of external snap ring pliers into the power outlet receptacle base and engage the tips of the pliers with the retaining bosses of the mount. 5. Squeeze the pliers to disengage the mount retaining bosses from the receptacle base and, using a gentle rocking motion, pull the pliers and the receptacle base out of the mount. It may also help to reach through to the back side of the power outlet and apply some force to help work the base out. 6. Remove the power outlet mount from the D-pillar trim. INSTALLATION 1. Install the power outlet mount into the D-pillar trim. 2. Align the splines on the outside of the cigar lighter or power outlet receptacle base connector receptacle with the grooves on the inside of the mount. 3. Press firmly on the cigar lighter or power outlet receptacle base until the retaining bosses of the mount are fully engaged in their receptacles. 4. Install the protective cap into the power outlet receptacle base. 5. Install the cup holder in the D-pillar trim panel. 6. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions Circuit Breaker: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5219 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5220 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5221 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5222 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5223 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5224 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5225 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5226 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5227 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5228 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5229 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5230 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5231 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5232 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5233 Circuit Breaker: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5234 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5235 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5236 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5237 Circuit Breaker: Electrical Diagrams 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5238 8w-12-3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5239 8w-12-5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Page 5240 Circuit Breaker: Description and Operation An automatic resetting circuit breaker in the junction block is used to protect the power seat system circuit. The circuit breaker can protect the system from a short circuit, or from an overload condition caused by an obstructed or stuck seat adjuster. The circuit breaker cannot be repaired and, if faulty or damaged, it must be replaced. An automatic resetting circuit breaker in the junction block is used to protect the power window system circuit. The circuit breaker can protect the system from a short circuit, or from an overload condition caused by an obstructed or stuck window glass or regulator. The circuit breaker cannot be repaired and, if faulty, it must be replaced. 1. Locate the correct circuit breaker in the junction block. Pull out the circuit breaker slightly, but be certain that the circuit breaker terminals still contact the terminals in the junction block cavities. 2. Connect the negative lead of a 12-volt DC voltmeter to a good ground. 3. With the voltmeter positive lead, check both terminals of the circuit breaker for battery voltage. If only one terminal has battery voltage, the circuit breaker is faulty and must be replaced. If neither terminal has battery voltage, repair the open circuit from the Power Distribution Center (PDC) as required. 1. Locate the circuit breaker in the junction block. Pull out the circuit breaker slightly, but be certain that the circuit breaker terminals still contact the terminals in the junction block cavities. 2. Connect the negative lead of a 12-volt DC voltmeter to a good ground. 3. With the voltmeter positive lead, check both terminals of the circuit breaker for battery voltage. If only one terminal has battery voltage, the circuit breaker is faulty and must be replaced. If neither terminal has battery voltage, repair the open circuit from the Power Distribution Center (PDC) as required. If the circuit breaker checks OK, but no power windows operate, see Power Window System in the Diagnosis and Testing. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Locations Power Distribution Center (PDC): Locations The molded plastic PDC housing is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 8w-10-8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 5246 Power Distribution Center (PDC): Diagrams C107 C107 C107 (in PDC) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 5247 8w-10-9 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 5248 Power Distribution Center (PDC): Diagrams Joint Connector 1 Joint Connector No. 1 (in PDC) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 5249 8w-10-10 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 5250 Power Distribution Center (PDC): Diagrams Joint Connector 2 Joint Connector No. 2 (in PDC) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 5251 8w-10-11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 5252 Power Distribution Center (PDC): Diagrams 8w-10-8 C107 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 5253 C107 (in PDC) 8w-10-9 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 5254 Joint Connector No. 1 (in PDC) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 5255 8w-10-10 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 5256 Joint Connector No. 2 (in PDC) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 5257 8w-10-11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 5258 Joint Connector No. 3 (in PDC) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 5259 8w-10-12 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 5260 Joint Connector No. 4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Page 5261 Power Distribution Center (PDC): Description and Operation POWER DISTRIBUTION This covers the various standard and optional power distribution components used on this model. The power distribution system for this vehicle consists of the following components: Power Distribution Center (PDC) - Junction Block (JB) - Relay and Fuse Block. The power distribution system also incorporates various types of circuit control and protection features, including: Automatic resetting circuit breakers - Blade-type fuses - Cartridge fuses - Circuit splice blocks - Flashers - Relays. Following are general descriptions of the major components in the power distribution system. See the owner's manual in the vehicle glove box for more information on the features and use of all of the power distribution system components. The power distribution system for this vehicle is designed to provide safe, reliable, and centralized distribution points for the electrical current required to operate all of the many standard and optional factory-installed electrical and electronic powertrain, chassis, safety, security, comfort and convenience systems. At the same time, the power distribution system was designed to provide ready access to these electrical distribution points for the vehicle technician to use when conducting diagnosis and repair of faulty circuits. The power distribution system can also prove useful for the sourcing of additional electrical circuits that may be required to provide the electrical current needed to operate many accessories that the vehicle owner may choose to have installed in the aftermarket. Fig. 1 Cigar Lighter And Power Outlet CIGAR LIGHTER OUTLET A cigar lighter is standard equipment on this model. The cigar lighter is installed in the instrument panel lower bezel, which is located near the center of the instrument panel, below the radio. The cigar lighter base is secured by a snap fit within the instrument panel lower bezel. The cigar lighter knob and heating element unit and the cigar lighter receptacle unit are available for service. These components cannot be repaired and, if faulty or damaged, they must be replaced. The cigar lighter consists of two major components a knob and heating element unit, and the cigar lighter base or receptacle shell. The receptacle shell is connected to ground, and an insulated contact ii] the bottom of the shell is connected to battery current. The cigar lighter receives battery voltage from a fuse in the junction block only when the ignition switch is in the Accessory or ON positions. The knob and heating element are encased within a spring-loaded housing, which also features a sliding protective heat shield. When the knob and heating element are inserted in the receptacle shell, the heating element resistor coil is grounded through its housing to the receptacle shell. If the cigar lighter knob is pushed inward, the heat shield slides up toward the knob exposing the heating element, and the heating element extends from the housing toward the insulated contact in the bottom of the receptacle shell. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Page 5262 Two small spring-clip retainers are located on either side of the insulated contact inside the bottom of the receptacle shell. These clips engage and hold the heating element against the insulated contact long enough for the resistor coil to heat up. When the heating element is engaged with the contact, battery current can flow through the resistor coil to ground, causing the resistor coil to heat. When the resistor coil becomes sufficiently heated, excess heat radiates from the heating element causing the spring-clips to expand. Once the spring-clips expand far enough to release the heating element, the spring-loaded housing forces the knob and heating element to pop back outward to their relaxed position. When the cigar lighter knob and element are pulled out of the receptacle shell, the protective heat shield slides downward on the housing so that the heating element is recessed and shielded around its circumference for safety. CIRCUIT BREAKER An automatic resetting circuit breaker in the junction block is used to protect the power seat system circuit. The circuit breaker can protect the system from a short circuit, or from an overload condition caused by an obstructed or stuck seat adjuster. The circuit breaker cannot be repaired and, if faulty or damaged, it must be replaced. An automatic resetting circuit breaker in the junction block is used to protect the power window system circuit. The circuit breaker can protect the system from a short circuit, or from an overload condition caused by an obstructed or stuck window glass or regulator. The circuit breaker cannot be repaired and, if faulty, it must be replaced. Circuit Breaker 1. Locate the correct circuit breaker in the junction block. Pull out the circuit breaker slightly, but be certain that the circuit breaker terminals still contact the terminals in the junction block cavities. 2. Connect the negative lead of a 12-volt DC voltmeter to a good ground. 3. With the voltmeter positive lead, check both terminals of the circuit breaker for battery voltage. If only one terminal has battery voltage, the circuit breaker is faulty and must be replaced. If neither terminal has battery voltage, repair the open circuit from the Power Distribution Center (PDC) as required. Circuit Breaker 1. Locate the circuit breaker in the junction block. Pull out the circuit breaker slightly, but be certain that the circuit breaker terminals still contact the terminals in the junction block cavities. 2. Connect the negative lead of a 12-volt DC voltmeter to a good ground. 3. With the voltmeter positive lead, check both terminals of the circuit breaker for battery voltage. If only one terminal has battery voltage, the circuit breaker is faulty and must be replaced. If neither terminal has battery voltage, repair the open circuit from the Power Distribution Center (PDC) as required. If the circuit breaker checks OK, but no power windows operate, see Power Window System in the Diagnosis and Testing. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Page 5263 Fig. 3 Ignition-Off Draw Fuse - Typical IOD FUSE All vehicles are equipped with an Ignition-Off Draw (IOD) fuse (Fig. 3) that is disconnected within the Junction Block (JB) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the JB as part of the preparation procedures performed just prior to new vehicle delivery. The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed to provide service access to the fuses in the JB. A finger recess is molded into the access panel for easy removal. An adhesive-backed fuse layout map is secured to the instrument panel side of the access panel to ensure proper fuse identification. The IOD fuse is a 15 ampere mini blade-type fuse. The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in its JB cavity, and as a fuse holder that conveniently stores the fuse in the same JB cavity after it has been disconnected. The term ignition-off draw identifies a normal condition where power is being drained from the battery with the ignition switch in the OFF position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the OFF position, including the clock. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from JB fuse cavity 12 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse serves no useful purpose to the dealer technician in the service or diagnosis of any vehicle system or condition, other than the same purpose as that of any other standard circuit protection device. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Refer to Battery for the location of additional service information covering the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Page 5264 Fig. 5 Junction Block Location JUNCTION BLOCK An electrical Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover (Fig. 5). The JB serves to simplify and centralize numerous electrical components, and to distribute electrical current to many of the accessory systems in the vehicle. It also eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. The JB houses up to nineteen blade-type fuses (two standard-type and seventeen mini-type), up to two blade- type automatic resetting circuit breakers, and two International Standards Organization (ISO) relays (one standard-type and one micro-type). The molded plastic JB housing has integral mounting brackets that are secured with two screws to the left instrument panel end bracket. The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed for service of the JB. A fuse puller and spare fuse holders are located on the back of the fuse access cover, as well as an adhesive- backed fuse layout map to ensure proper fuse identification. The JB unit cannot be repaired and is only serviced as an assembly. If any internal circuit or the JB housing is faulty or damaged, the entire JB unit must be replaced. All of the circuits entering and leaving the JB do so through up to nine wire harness connectors, which are connected to the JB through integral connector receptacles molded into the JB housing. Internal connection of all of the JB circuits is accomplished by an intricate combination of hard wiring and bus bars. Refer to Junction Block for the location of complete JB circuit diagrams. Fig. 8 Power Distribution Center Location - Typical Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Page 5265 POWER DISTRIBUTION CENTER All of the electrical current distributed throughout this vehicle is directed through the standard equipment Power Distribution Center (PDC) (Fig. 8). The molded plastic PDC housing is located in the left front corner of the engine compartment, just behind the battery. The PDC houses the generator cartridge fuse and up to ten maxi-type cartridge fuses, which replace all in-line fusible links. The PDC also houses up to seven blade-type mini fuses, up to thirteen International Standards Organization (ISO) relays (one standard-type and twelve micro-type), two joint connectors (one sixteen-way and one twenty-six-way) and a sixteen-way engine wire harness in-line connector. The PDC housing is secured in the engine compartment at three points. Integral mounts on the front and inboard sides of the PDC housing engage and latch to stanchions that are integral to the molded plastic battery tray. An integral bracket on the rear of the PDC housing is secured with a screw to the top of the left front inner wheel house. The PDC housing has a molded plastic cover that includes two integral latches, one on each side. The PDC cover is easily opened and removed for service access and has a convenient fuse and relay layout map integral to the inside surface of the cover to ensure proper component identification. The PDC unit cannot be repaired and is only serviced as a unit with the headlamp and dash wire harness. If the internal circuits or the PDC housing are faulty or damaged, the headlamp and dash wire harness unit must be replaced. All of the current from the battery and the generator output enters the PDC through one cable with eyelets that are secured with a nut to the one B(+) terminal stud located just inside the inboard side of the PDC housing. The PDC cover is unlatched and removed to access the battery and generator output connection B(+) terminal studs, the fuses, the relays, the joint connectors and the engine wire harness inline connector. Internal connection of all of the PDC circuits is accomplished by an intricate combination of hard wiring and bus bars. POWER OUTLET An accessory power outlet is optional equipment on this model. The power outlet is installed in the instrument panel lower bezel, which is located near the center of the instrument panel, below the radio. The power outlet base is secured by a snap fit within the instrument panel lower bezel. A plastic protective cap snaps into the power outlet base when the power outlet is not being used, and hangs from the power outlet base mount by an integral bail strap while the power outlet is in use. The power outlet receptacle unit and the accessory power outlet protective cap are available for service. The power outlet receptacle cannot be repaired and, if faulty or damaged, it must be replaced. The power outlet base or receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The power outlet receives battery voltage from a fuse in the Power Distribution Center (PDC) at all times. While the power outlet is very similar to a cigar lighter base unit, it does not include the two small spring-clip retainers inside the bottom of the receptacle shell that are used to secure the cigar lighter heating element to the insulated contact. Fig. 10 Relay And Fuse Block Location RELAY CENTER The relay and fuse block is snap fit onto mounting tabs located on the end of the Junction Block (JB) nearest to the dash panel, under the left outboard end of the instrument panel (Fig. 10). The relay and fuse block provides additional capacity for distribution and control of electrical current for some of the accessory systems that are unique to this vehicle, and which could not be accommodated by the JB or the Power Distribution Center (PDC). The relay and fuse block has cavities for up to four additional blade4ype mini fuses, the electronic combination flasher, and three additional International Standards Organization relays (one standard-type and two micro-type). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Page 5266 The relay and fuse block components are accessed for service by removing the steering column opening cover from the instrument panel. The relay and fuse block is then disengaged from the JB mounting tabs and pulled out from under the instrument panel. Service replacement of the relay and fuse block unit requires instrument panel assembly removal. The relay and fuse block unit cannot be repaired and is only serviced as a unit with the instrument panel wire harness assembly. If the relay and fuse block housing or its internal circuits are faulty or damaged, the entire instrument panel wire harness unit must be replaced. The relay and fuse block is integral to the instrument panel wire harness, and all circuits entering or leaving this module do so through the instrument panel wire harness. Internal connection of all of the relay and fuse block circuits is accomplished by hard wiring. Refer to Fuse/Fuse Block for the location of complete circuit diagrams and cavity assignments for the relay and fuse block. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Page 5267 Power Distribution Center (PDC): Service and Repair REMOVAL The Power Distribution Center (PDC) is serviced as a unit with the headlamp and dash wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and headlamp and dash wire harness unit must be replaced. 1. Disconnect and isolate the battery negative cable. 2. Disconnect each of the headlamp and dash wire harness connectors. Refer to Connector Locations in the Wiring for the location of more information on the headlamp and dash wire harness connector locations. 3. Remove all of the fasteners that secure each of the headlamp and dash wire harness ground eyelets to the vehicle body and chassis components. Refer to Connector Locations for the location of more information on the ground eyelet locations. 4. Disengage each of the retainers that secure the headlamp and dash wire harness to the vehicle body and chassis components. Refer to Connector Locations for the location of more information on the headlamp and dash wire harness retainer locations. 5. Unlatch and remove the cover from the PDC. 6. Disconnect the engine wire harness in-line connector from the PDC connector receptacle. 7. Slide the engine wire harness retainer clip upward and disengage the harness from the trough on the rear of the PDC housing. 8. Remove the nut that secures the eyelet of the battery negative cable generator output take out to the rearward B(+) terminal stud in the PDC and remove the eyelet from the stud. 9. Remove the nut that secures the eyelet of the battery positive cable PDC take out to the B(+) terminal stud in the PDC and remove the eyelet from the stud. 10. Remove the screw that secures the PDC housing to the left front fender wheel housing. 11. Disengage the latches for the two PDC mounts and lift the unit OFF of the battery tray stanchions. 12. Remove the PDC and the headlamp and dash wire harness from the engine compartment as a unit. INSTALLATION The Power Distribution Center (PDC) is serviced as a unit with the headlamp and dash wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and headlamp and dash wire harness unit must be replaced. NOTE: If the PDC is being replaced with a new unit, be certain to transfer each of the blade-type fuses, cartridge fuses and relays from the faulty PDC to the proper cavities of the replacement PDC. Refer to Power Distribution for the location of complete PDC circuit diagrams and cavity assignments. 1. Position the PDC and the headlamp and dash wire harness unit in the engine compartment. 2. Install the two PDC mounts onto the two stanchions of the battery tray. 3. Install and tighten the screw that secures the PDC housing to the left front fender wheel housing. Tighten the screw to 7.9 Nm (70 in. lbs.). 4. Install the eyelet of the battery positive cable PDC take out onto the forward B(+) terminal stud in the PDC. 5. Install and tighten the nut that secures the eyelet of the battery positive cable PDC take out to the forward B(+) terminal stud in the PDC. Tighten the nut to 9 Nm (80 in. lbs.). 6. Install the eyelet of the battery negative cable generator output take out onto the rearward B(+) terminal stud in the PDC. 7. Install and tighten the nut that secures the eyelet of the battery negative cable generator output take out to the rearward B(+) terminal stud in the PDC. Tighten the nut to 9 Nm (80 in. lbs.). 8. Engage the engine wire harness in the trough on the back of the PDC housing and secure it with the retainer clip. 9. Reconnect the engine wire harness in-line connector to the PDC in-line connector receptacle. 10. Install and latch the cover onto the PDC. 11. Engage each of the retainers that secure the headlamp and dash wire harness to the vehicle body and chassis components. Refer to Connector Locations for the location of more information on the headlamp and dash wire harness retainer locations. 12. Install all of the fasteners that secure each of the headlamp and dash wire harness ground eyelets to the vehicle body and chassis components. Refer to Connector Locations for the location of more information on the ground eyelet locations. 13. Reconnect each of the headlamp and dash wire harness connectors. Refer to Connector Locations for the location of more information on the headlamp and dash wire harness connector locations. 14. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Junction Block Fuse: Locations Junction Block Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Junction Block > Page 5272 Fuse: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block Fuse: Diagrams Junction Block 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 5275 8w-12-3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 5276 8w-12-4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 5277 8w-12-5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 5278 Junction Block C1 Junction Block C2 Junction Block C3 Junction Block C4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 5279 Junction Block C5 Junction Block C6 Junction Block C7 Junction Block C8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 5280 Junction Block C9 Junction Block C10 Junction Block C11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 5281 Junction Block C12 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 5282 Fuse: Diagrams Power Distribution Center 8w-10-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 5283 8w-10-3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 5284 8w-10-4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 5285 8w-10-5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 5286 8w-10-6 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 5287 8w-10-7 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 5288 8w-10-8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 5289 8w-10-9 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 5290 8w-10-10 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 5291 8w-10-11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 5292 8w-10-12 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Junction Block Fuse: Application and ID Junction Block Junction Block Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Junction Block > Page 5295 Fuse: Application and ID Power Distribution Center Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Junction Block Fuse Block: Locations Junction Block Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Junction Block > Page 5300 Fuse Block: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5303 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5304 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5305 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5306 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5307 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5308 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5309 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5310 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5311 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5312 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5313 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5314 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5315 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5316 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5317 Fuse Block: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5318 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5319 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5320 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5321 Fuse Block: Connector Views Junction Block 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5322 8w-12-3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5323 8w-12-4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5324 8w-12-5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5325 Junction Block C1 Junction Block C2 Junction Block C3 Junction Block C4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5326 Junction Block C5 Junction Block C6 Junction Block C7 Junction Block C8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5327 Junction Block C9 Junction Block C10 Junction Block C11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5328 Junction Block C12 Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5329 8w-10-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5330 8w-10-3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5331 8w-10-4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5332 8w-10-5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5333 8w-10-6 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5334 8w-10-7 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5335 8w-10-8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5336 8w-10-9 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5337 8w-10-10 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5338 8w-10-11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5339 8w-10-12 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5340 Fuse Block: Electrical Diagrams 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5341 8w-12-3 Wiring Diagrams Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5342 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5343 8w-12-6 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5344 8w-12-7 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5345 8w-12-8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5346 8w-12-9 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5347 8w-12-10 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5348 8w-12-11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5349 8w-12-12 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5350 8w-12-13 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5351 8w-12-14 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5352 8w-12-15 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5353 8w-12-16 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5354 8w-12-17 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5355 8w-12-18 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5356 8w-12-19 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5357 8w-12-20 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5358 8w-12-21 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5359 8w-12-22 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams See: Diagrams/Electrical Diagrams Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 5360 Fuse Block: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Junction Block Fuse Block: Application and ID Junction Block Junction Block Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Junction Block > Page 5363 Fuse Block: Application and ID Power Distribution Center Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Page 5364 Fuse Block: Description and Operation Fig. 5 Junction Block Location An electrical Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover (Fig. 5). The JB serves to simplify and centralize numerous electrical components, and to distribute electrical current to many of the accessory systems in the vehicle. It also eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. The JB houses up to nineteen blade-type fuses (two standard-type and seventeen mini-type), up to two blade- type automatic resetting circuit breakers, and two International Standards Organization (ISO) relays (one standard-type and one micro-type). The molded plastic JB housing has integral mounting brackets that are secured with two screws to the left instrument panel end bracket. The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed for service of the JB. A fuse puller and spare fuse holders are located on the back of the fuse access cover, as well as an adhesive-backed fuse layout map to ensure proper fuse identification. The JB unit cannot be repaired and is only serviced as an assembly. If any internal circuit or the JB housing is faulty or damaged, the entire JB unit must be replaced. All of the circuits entering and leaving the JB do so through up to nine wire harness connectors, which are connected to the JB through integral connector receptacles molded into the JB housing. Internal connection of all of the JB circuits is accomplished by an intricate combination of hard wiring and bus bars. Refer to Junction Block for the location of complete JB circuit diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Page 5365 Fuse Block: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Fig. 6 Fuse Access Panel Remove/Install 2. Remove the fuse access panel by unsnapping it from the left outboard end of the instrument panel (Fig. 6). 3. Reach through the instrument panel fuse access panel opening to access and remove the one screw that secures the Junction Block (JB) to the left instrument panel end bracket. 4. Remove the steering column opening cover from the instrument panel. Refer to Steering Column Opening Cover for the location of the steering column opening cover removal procedures. Fig. 7 Junction Block Remove/Install 5. Reach through the outboard side of the instrument panel steering column opening to access and disconnect all of the wire harness connectors from the JB connector receptacles (Fig. 7). 6. Reach through the outboard side of the instrument panel steering column opening to access and remove the relay and fuse block from the JB. Push Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Page 5366 the relay and fuse block towards the left end of the instrument panel to disengage its mounting slots from the tabs on the JB. 7. Reach through the outboard side of the instrument panel steering column opening to access and remove the one screw that secures the JB to the left instrument panel end bracket. 8. Reach through the outboard side of the instrument panel steering column opening to remove the JB from the left instrument panel end bracket. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: If the Junction Block (JB) is being replaced with a new unit, be certain to transfer each of the fuses, circuit breakers and relays from the faulty JB to the proper cavities of the replacement JB. Refer to Junction Block for the location of complete circuit diagrams and cavity assignments for the JB. 1. Reach through the outboard side of the instrument panel steering column opening to position the JB onto the left instrument panel end bracket. 2. Reach through the outboard side of the instrument panel steering column opening to install and tighten the one screw that secures the JB to the left instrument panel end bracket. Tighten the screw to 2.2 Nm (20 in. lbs.). 3. Reach through the outboard side of the instrument panel steering column opening to access and install the relay and fuse block onto the JB by engaging the relay and fuse block mounting slots with the tabs on the JB. 4. Reach through the outboard side of the instrument panel steering column opening to access and reconnect all of the wire harness connectors to the JB connector receptacles. 5. Install the steering column opening cover onto the instrument panel. Refer to Steering Column Opening Cover for the location of the steering column opening cover installation procedures. 6. Reach through the instrument panel fuse access panel opening to install and tighten the one screw that secures the junction block to the left instrument panel end bracket. Tighten the screw to 2.2 Nm (20 in. lbs.). 7. Install the fuse access panel by snapping it onto the left outboard end of the instrument panel. 8. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Recalls for Multiple Junction Connector: > F42 > Oct > 06 > Recall - Potential Interior Fire Technical Service Bulletin # F42 Date: 061001 Recall - Potential Interior Fire October 2006 Dealer Service Instructions for: Safety Recall F42 Unused Wiring Connector Models 2001-2003 (DN) Dodge Durango NOTE: This recall applies only to the above vehicles equipped with a 40/20/40 bench seat (sales code CBE). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject An unused wiring connector under the front seat on about 34,900 of the above vehicles may become contaminated with spilled fluid and/or debris. This may cause a short circuit, which can result in an interior fire. Repair The unused connector under the front seat must be inspected for corrosion/debris and cleaned as necessary. In addition, a connector seal with a plastic retainer clip must be installed on the unused connector. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Recalls for Multiple Junction Connector: > F42 > Oct > 06 > Recall - Potential Interior Fire > Page 5375 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Recalls for Multiple Junction Connector: > F42 > Oct > 06 > Recall - Potential Interior Fire > Page 5376 Use the labor operation number and time allowance shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure 1. Open the driver's door and move the driver's seat to the full rearward position. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Recalls for Multiple Junction Connector: > F42 > Oct > 06 > Recall - Potential Interior Fire > Page 5377 2. Locate the unused electrical connector under the driver's seat near the transmission tunnel (Figure 1). NOTE: If the male side of the unused connector is missing, order male connector CBDPF422 for 2001 model year vehicles or CBDPF423 for 2002/2003 model year vehicles. 3. Slide the red locking tab towards the driver's side of the vehicle to release the primary lock on the connector. 4. Squeeze the tail end of the male connector to release the secondary connector lock and pull the connector apart. 5. Inspect the wiring harness side of the connector for corrosion and/or debris. If corrosion and/or debris is found, use Electrolyte Detection and Neutralizing Spray (P/N CBEJD201) to clean the corrosion and/or debris from the connector. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Recalls for Multiple Junction Connector: > F42 > Oct > 06 > Recall - Potential Interior Fire > Page 5378 6. Install the connector end seal, retainer cap and cavity plugs into the empty male connector (removed in Step 4) as shown in Figure 2. 7. Install the male connector onto the unused wiring harness connector and engage the red lock tab by sliding the lock tab towards the passenger side of the vehicle (Figure 2). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Recalls for Multiple Junction Connector: > F42 > Oct > 06 > Recall - Potential Interior Fire > Page 5379 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Recalls for Multiple Junction Connector: > NHTSA06V339000 > Sep > 06 > Recall 06V339000: Console Wiring Connector Modification Multiple Junction Connector: Recalls Recall 06V339000: Console Wiring Connector Modification MAKE/MODELS: MODEL/BUILD YEARS: Dodge/Durango 2001-2003 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 06V339000 MFG'S REPORT DATE: September 06, 2006 COMPONENT: Electrical System POTENTIAL NUMBER OF UNITS AFFECTED: 35103 SUMMARY: On certain sport utility vehicles equipped with front bench seats only, if fluid is spilled from the floor mounted cup holder, an unused console power outlet connector located under the seat may become contaminated. CONSEQUENCE: This may allow development of a high resistive short circuit in the connector, which could eventually lead to a fire. REMEDY: Dealers will inspect the console wiring connector for corrosion, clean as required, and install a cap to prevent additional fluid from contaminating the connector free of charge. The manufacturer has not yet provided an owner notification schedule. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. F42. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > F42 > Oct > 06 > Recall Potential Interior Fire Technical Service Bulletin # F42 Date: 061001 Recall - Potential Interior Fire October 2006 Dealer Service Instructions for: Safety Recall F42 Unused Wiring Connector Models 2001-2003 (DN) Dodge Durango NOTE: This recall applies only to the above vehicles equipped with a 40/20/40 bench seat (sales code CBE). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject An unused wiring connector under the front seat on about 34,900 of the above vehicles may become contaminated with spilled fluid and/or debris. This may cause a short circuit, which can result in an interior fire. Repair The unused connector under the front seat must be inspected for corrosion/debris and cleaned as necessary. In addition, a connector seal with a plastic retainer clip must be installed on the unused connector. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > F42 > Oct > 06 > Recall Potential Interior Fire > Page 5389 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > F42 > Oct > 06 > Recall Potential Interior Fire > Page 5390 Use the labor operation number and time allowance shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure 1. Open the driver's door and move the driver's seat to the full rearward position. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > F42 > Oct > 06 > Recall Potential Interior Fire > Page 5391 2. Locate the unused electrical connector under the driver's seat near the transmission tunnel (Figure 1). NOTE: If the male side of the unused connector is missing, order male connector CBDPF422 for 2001 model year vehicles or CBDPF423 for 2002/2003 model year vehicles. 3. Slide the red locking tab towards the driver's side of the vehicle to release the primary lock on the connector. 4. Squeeze the tail end of the male connector to release the secondary connector lock and pull the connector apart. 5. Inspect the wiring harness side of the connector for corrosion and/or debris. If corrosion and/or debris is found, use Electrolyte Detection and Neutralizing Spray (P/N CBEJD201) to clean the corrosion and/or debris from the connector. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > F42 > Oct > 06 > Recall Potential Interior Fire > Page 5392 6. Install the connector end seal, retainer cap and cavity plugs into the empty male connector (removed in Step 4) as shown in Figure 2. 7. Install the male connector onto the unused wiring harness connector and engage the red lock tab by sliding the lock tab towards the passenger side of the vehicle (Figure 2). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > F42 > Oct > 06 > Recall Potential Interior Fire > Page 5393 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > NHTSA06V339000 > Sep > 06 > Recall 06V339000: Console Wiring Connector Modification Multiple Junction Connector: All Technical Service Bulletins Recall 06V339000: Console Wiring Connector Modification MAKE/MODELS: MODEL/BUILD YEARS: Dodge/Durango 2001-2003 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 06V339000 MFG'S REPORT DATE: September 06, 2006 COMPONENT: Electrical System POTENTIAL NUMBER OF UNITS AFFECTED: 35103 SUMMARY: On certain sport utility vehicles equipped with front bench seats only, if fluid is spilled from the floor mounted cup holder, an unused console power outlet connector located under the seat may become contaminated. CONSEQUENCE: This may allow development of a high resistive short circuit in the connector, which could eventually lead to a fire. REMEDY: Dealers will inspect the console wiring connector for corrosion, clean as required, and install a cap to prevent additional fluid from contaminating the connector free of charge. The manufacturer has not yet provided an owner notification schedule. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. F42. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Joint Connector No. 1 and No. 2 Multiple Junction Connector: Diagrams Joint Connector No. 1 and No. 2 Joint Connector No.1 (In PDC) Joint Connector No.2 (In PDC) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Joint Connector No. 1 and No. 2 > Page 5400 Multiple Junction Connector: Diagrams Joint Connector No. 3 and No. 4 Joint Connector No.3 (In PDC) Joint Connector No.4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Locations Ignition Off-Draw (IOD) Fuse: Locations The IOD fuse is located in the junction block. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Locations > Page 5404 Ignition Off-Draw (IOD) Fuse: Description and Operation IGNITION-OFF DRAW FUSE All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is removed when the vehicle is shipped from the factory. This fuse feeds various accessories that require battery current when the ignition switch is in the OFF position, including the clock. The IOD fuse is removed to prevent battery discharge during vehicle storage. When removing or installing the IOD fuse, it is important that the ignition switch be in the OFF position. Failure to place the ignition switch in the OFF position can cause the radio display to become scram- bled when the IOD fuse is removed and replaced. Removing and replacing the IOD fuse again, with the ignition switch in the OFF position, will correct the scrambled display condition. The IOD fuse should be checked if the radio or clock displays are inoperative. The IOD fuse is located in the junction block. Refer to the fuse layout label on the back of the instrument panel fuse access panel for IOD fuse identification and location. Fig. 3 Ignition-Off Draw Fuse - Typical IOD FUSE All vehicles are equipped with an Ignition-Off Draw (IOD) fuse (Fig. 3) that is disconnected within the Junction Block (JB) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the JB as part of the preparation procedures performed just prior to new vehicle delivery. The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed to provide service access to the fuses in the JB. A finger recess is molded into the access panel for easy removal. An adhesive-backed fuse layout map is secured to the instrument panel side of the access panel to ensure proper fuse identification. The IOD fuse is a 15 ampere mini blade-type fuse. The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in its JB cavity, and as a fuse holder that conveniently stores the fuse in the same JB cavity after it has been disconnected. The term ignition-off draw identifies a normal condition where power is being drained from the battery with the ignition switch in the OFF position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the OFF position, including the clock. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from JB fuse cavity 12 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse serves no useful purpose to the dealer technician in the service or diagnosis of any vehicle system or condition, other than the same purpose as that of any other standard circuit protection device. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Locations > Page 5405 The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Refer to Battery for the location of additional service information covering the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Locations > Page 5406 Ignition Off-Draw (IOD) Fuse: Testing and Inspection Ignition-Off Draw Test The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the OFF position. A normal vehicle electrical system will draw from five to thirty-five milliamperes (0.005 to 0.035 ampere) with the ignition switch in the OFF position, and all non-ignition controlled circuits in proper working order. Up to thirty-five milliamperes are needed to enable the memory functions for the Powertrain Control Module (PCM), digital clock, electronically tuned radio, and other modules which may vary with the vehicle equipment. A vehicle that has not been operated for approximately twenty days, may discharge the battery to an inadequate level. When a vehicle will not be used for twenty days or more (stored), remove the IOD fuse from the Power Distribution Center (PDC). This will reduce battery discharging. Excessive IOD can be caused by: - Electrical items left ON. - Faulty or improperly adjusted switches. - Faulty or shorted electronic modules and components. - An internally shorted generator. - Intermittent shorts in the wiring. If the IOD is over thirty-five milliamperes, the problem must be found and corrected before replacing a battery. In most cases, the battery can be charged and returned to service after the excessive IOD condition has been corrected. Electronic Module Ignition-Off-Draw (IOD) Table 1. Verify that all electrical accessories are OFF. Turn OFF all lamps, remove the ignition key, and close all doors. If the vehicle is equipped with an illuminated entry system or an electronically tuned radio, allow the electronic timer function of these systems to automatically shut off (time out). This may take up to three minutes. See the Electronic Module Ignition-Off Draw Table for more information. 2. Determine that the underhood lamp is operating properly, then disconnect the lamp wire harness connector or remove the lamp bulb. 3. Disconnect the battery negative cable. 4. Set an electronic digital multi-meter to its highest amperage scale. Connect the multi-meter between the disconnected battery negative cable terminal clamp and the battery negative terminal post. Make sure that the doors remain closed so that the illuminated entry system is not activated. The multi-meter amperage reading may remain high for up to three minutes, or may not give any reading at all while set in the highest amperage scale, depending upon the electrical equipment in the vehicle. The multi-meter leads must be securely clamped to the battery negative cable terminal clamp and the battery negative terminal post. If continuity between the battery negative terminal post and the negative cable terminal clamp is lost during any part of the IOD test, the electronic timer function will be activated and all of the tests will have to be repeated. 5. After about three minutes, the high-amperage IOD reading on the multi-meter should become very low or nonexistent, depending upon the electrical equipment in the vehicle. If the amperage reading remains high, remove and replace each fuse or circuit breaker in the Power Distribution Center (PDC) and then in the Junction Block (JB), one at a time until the amperage reading becomes very low, or nonexistent. This will isolate each circuit and identify the circuit that is the source of the high-amperage IOD. If the amperage reading remains high after removing and replacing each fuse and circuit breaker, disconnect the wire harness from the generator. If the amperage reading now becomes very low or nonexistent, refer to Charging System for the proper charging system diagnosis and testing procedures. After the high-amperage IOD has been corrected, switch the multi-meter to progressively lower amperage scales and, if necessary, repeat the fuse and circuit breaker remove-and-replace process to identify and correct all sources of excessive IOD. It is now safe to select the lowest milliampere scale of the multi-meter to check the low- amperage IOD. CAUTION: Do not open any doors, or turn ON any electrical accessories with the lowest milliampere scale selected, or the multi-meter may be Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Locations > Page 5407 damaged. 6. Observe the multi-meter reading. The low-amperage IOD should not exceed thirty-five milliamperes (0.035 ampere). If the current draw exceeds thirty-five milliamperes, isolate each circuit using the fuse and circuit breaker remove-and-replace process in Step 5. The multi-meter reading will drop to within the acceptable limit when the source of the excessive current draw is disconnected. Repair this circuit as required; whether a wiring short, incorrect switch adjustment, or a component failure is at fault. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Locations > Page 5408 Ignition Off-Draw (IOD) Fuse: Service and Repair Fig. 4 Ignition-Off Draw Fuse - Typical REMOVAL The Ignition-Off Draw (IOD) fuse is disconnected from Junction Block (JB) fuse cavity 12 (Fig. 4) when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. NOTE: When removing or installing the IOD fuse, it is important that the ignition switch be in the OFF position. Failure to place the ignition switch in the OFF position can cause the radio display to become scrambled when the IOD fuse is installed. Removing and installing the IOD fuse again with the ignition switch in the Oft position will usually correct the scrambled radio display condition. 1. Turn the ignition switch to the OFF position. 2. Remove the fuse access panel by unsnapping it from the left outboard end of the instrument panel. 3. Grasp the upper and lower tabs of the IOD fuse holder unit in fuse cavity 12 of the JB between the thumb and forefinger and pull the unit firmly outward. 4. Install the fuse access panel by snapping it onto the left outboard end of the instrument panel. INSTALLATION The Ignition-Off Draw (IOD) fuse is disconnected from Junction Block (JB) fuse cavity 12 (Fig. 4) when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. 1. Turn the ignition switch to the OFF position. 2. Remove the fuse access panel by unsnapping it from the left outboard end of the instrument panel. 3. To install the IOD fuse, use a thumb to press the IOD fuse holder unit in fuse cavity 12 firmly into the JB. 4. Install the fuse access panel by snapping it onto the left outboard end of the instrument panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block Relay Box: Locations Junction Block Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block > Page 5414 Relay Box: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block Relay Box: Diagrams Junction Block 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5417 8w-12-3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5418 8w-12-4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5419 8w-12-5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5420 Junction Block C1 Junction Block C2 Junction Block C3 Junction Block C4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5421 Junction Block C5 Junction Block C6 Junction Block C7 Junction Block C8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5422 Junction Block C9 Junction Block C10 Junction Block C11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5423 Junction Block C12 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5424 Relay Box: Diagrams Power Distribution Center 8w-10-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5425 8w-10-3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5426 8w-10-4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5427 8w-10-5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5428 8w-10-6 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5429 8w-10-7 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5430 8w-10-8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5431 8w-10-9 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5432 8w-10-10 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5433 8w-10-11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5434 8w-10-12 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Page 5435 Relay Box: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block Relay Box: Application and ID Junction Block Junction Block Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 5438 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 5439 Relay Box: Application and ID Power Distribution Center Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 5440 Relay Box: Description and Operation Fig. 10 Relay And Fuse Block Location RELAY CENTER The relay and fuse block is snap fit onto mounting tabs located on the end of the Junction Block (JB) nearest to the dash panel, under the left outboard end of the instrument panel (Fig. 10). The relay and fuse block provides additional capacity for distribution and control of electrical current for some of the accessory systems that are unique to this vehicle, and which could not be accommodated by the JB or the Power Distribution Center (PDC). The relay and fuse block has cavities for up to four additional blade4ype mini fuses, the electronic combination flasher, and three additional International Standards Organization relays (one standard-type and two micro-type). The relay and fuse block components are accessed for service by removing the steering column opening cover from the instrument panel. The relay and fuse block is then disengaged from the JB mounting tabs and pulled out from under the instrument panel. Service replacement of the relay and fuse block unit requires instrument panel assembly removal. The relay and fuse block unit cannot be repaired and is only serviced as a unit with the instrument panel wire harness assembly. If the relay and fuse block housing or its internal circuits are faulty or damaged, the entire instrument panel wire harness unit must be replaced. The relay and fuse block is integral to the instrument panel wire harness, and all circuits entering or leaving this module do so through the instrument panel wire harness. Internal connection of all of the relay and fuse block circuits is accomplished by hard wiring. Refer to Fuse/Fuse Block for the location of complete circuit diagrams and cavity assignments for the relay and fuse block. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 5441 Relay Box: Service and Repair REMOVAL The relay and fuse block is serviced as a unit with the instrument panel wire harness. If any internal circuit of the relay and fuse block or the relay and fuse block housing is faulty or damaged, the entire instrument panel wire harness unit must be replaced. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel assembly from the dash panel. Refer to Instrument Panel Assembly for the instrument panel assembly removal procedures. 3. Disconnect each of the instrument panel wire harness connectors. Refer to Connector Locations for the location of more information on the instrument panel wire harness connector locations. 4. Remove all of the fasteners that secure each of the instrument panel wire harness ground eyelets to the instrument panel components. Refer to Connector Locations for the location of more information on the ground eyelet locations. 5. Disengage each of the retainers that secure the instrument panel wire harness to the instrument panel components. Refer to Connector Locations for the location of more information on the instrument panel wire harness retainer locations. Fig. 11 Relay And Fuse Block Remove/Install 6. Push the relay and fuse block towards the left end of the instrument panel to disengage its mounting slots from the tabs on the Junction Block (JB) (Fig. 11). 7. Remove the relay and fuse block and the instrument panel wire harness from the instrument panel as a unit. INSTALLATION The relay and fuse block is serviced as a unit with the instrument panel wire harness. If any internal circuit of the relay and fuse block or the relay and fuse block housing is faulty or damaged, the entire instrument panel wire harness unit must be replaced. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: If the relay and fuse block is being replaced with a new unit, be certain to transfer each of the fuses, the flasher and the relays from the faulty relay and fuse block to the proper cavities of the replacement relay and fuse block. Refer to Fuse' Fuse Block for the location of complete relay and fuse block circuit diagrams and cavity assignments. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 5442 1. Position the relay and fuse block and the instrument panel wire harness onto the instrument panel. 2. Install the relay and fuse block by engaging its mounting slots onto the tabs on the Junction Block (JB). 3. Engage each of the retainers that secure the instrument panel wire harness to the instrument panel components. Refer to Connector Locations for the location of more information on the instrument panel wire harness retainer locations. 4. Install all of the fasteners that secure each of the instrument panel wire harness ground eyelets to the instrument panel components. Refer to Connector Locations for the location of more information on the ground eyelet locations. 5. Reconnect each of the instrument panel wire harness connectors. Refer to Connector Locations for the location of more information on the instrument panel wire harness connector locations. 6. Install the instrument panel assembly onto the dash panel. Refer to Instrument Panel Assembly for the location of the instrument panel assembly installation procedures. 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block Relay Box: Locations Junction Block Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block > Page 5447 Relay Box: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block Relay Box: Diagrams Junction Block 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5450 8w-12-3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5451 8w-12-4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5452 8w-12-5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5453 Junction Block C1 Junction Block C2 Junction Block C3 Junction Block C4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5454 Junction Block C5 Junction Block C6 Junction Block C7 Junction Block C8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5455 Junction Block C9 Junction Block C10 Junction Block C11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5456 Junction Block C12 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5457 Relay Box: Diagrams Power Distribution Center 8w-10-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5458 8w-10-3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5459 8w-10-4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5460 8w-10-5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5461 8w-10-6 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5462 8w-10-7 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5463 8w-10-8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5464 8w-10-9 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5465 8w-10-10 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5466 8w-10-11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5467 8w-10-12 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Page 5468 Relay Box: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block Relay Box: Application and ID Junction Block Junction Block Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 5471 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 5472 Relay Box: Application and ID Power Distribution Center Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 5473 Relay Box: Description and Operation Fig. 10 Relay And Fuse Block Location RELAY CENTER The relay and fuse block is snap fit onto mounting tabs located on the end of the Junction Block (JB) nearest to the dash panel, under the left outboard end of the instrument panel (Fig. 10). The relay and fuse block provides additional capacity for distribution and control of electrical current for some of the accessory systems that are unique to this vehicle, and which could not be accommodated by the JB or the Power Distribution Center (PDC). The relay and fuse block has cavities for up to four additional blade4ype mini fuses, the electronic combination flasher, and three additional International Standards Organization relays (one standard-type and two micro-type). The relay and fuse block components are accessed for service by removing the steering column opening cover from the instrument panel. The relay and fuse block is then disengaged from the JB mounting tabs and pulled out from under the instrument panel. Service replacement of the relay and fuse block unit requires instrument panel assembly removal. The relay and fuse block unit cannot be repaired and is only serviced as a unit with the instrument panel wire harness assembly. If the relay and fuse block housing or its internal circuits are faulty or damaged, the entire instrument panel wire harness unit must be replaced. The relay and fuse block is integral to the instrument panel wire harness, and all circuits entering or leaving this module do so through the instrument panel wire harness. Internal connection of all of the relay and fuse block circuits is accomplished by hard wiring. Refer to Fuse/Fuse Block for the location of complete circuit diagrams and cavity assignments for the relay and fuse block. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 5474 Relay Box: Service and Repair REMOVAL The relay and fuse block is serviced as a unit with the instrument panel wire harness. If any internal circuit of the relay and fuse block or the relay and fuse block housing is faulty or damaged, the entire instrument panel wire harness unit must be replaced. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel assembly from the dash panel. Refer to Instrument Panel Assembly for the instrument panel assembly removal procedures. 3. Disconnect each of the instrument panel wire harness connectors. Refer to Connector Locations for the location of more information on the instrument panel wire harness connector locations. 4. Remove all of the fasteners that secure each of the instrument panel wire harness ground eyelets to the instrument panel components. Refer to Connector Locations for the location of more information on the ground eyelet locations. 5. Disengage each of the retainers that secure the instrument panel wire harness to the instrument panel components. Refer to Connector Locations for the location of more information on the instrument panel wire harness retainer locations. Fig. 11 Relay And Fuse Block Remove/Install 6. Push the relay and fuse block towards the left end of the instrument panel to disengage its mounting slots from the tabs on the Junction Block (JB) (Fig. 11). 7. Remove the relay and fuse block and the instrument panel wire harness from the instrument panel as a unit. INSTALLATION The relay and fuse block is serviced as a unit with the instrument panel wire harness. If any internal circuit of the relay and fuse block or the relay and fuse block housing is faulty or damaged, the entire instrument panel wire harness unit must be replaced. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: If the relay and fuse block is being replaced with a new unit, be certain to transfer each of the fuses, the flasher and the relays from the faulty relay and fuse block to the proper cavities of the replacement relay and fuse block. Refer to Fuse' Fuse Block for the location of complete relay and fuse block circuit diagrams and cavity assignments. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 5475 1. Position the relay and fuse block and the instrument panel wire harness onto the instrument panel. 2. Install the relay and fuse block by engaging its mounting slots onto the tabs on the Junction Block (JB). 3. Engage each of the retainers that secure the instrument panel wire harness to the instrument panel components. Refer to Connector Locations for the location of more information on the instrument panel wire harness retainer locations. 4. Install all of the fasteners that secure each of the instrument panel wire harness ground eyelets to the instrument panel components. Refer to Connector Locations for the location of more information on the ground eyelet locations. 5. Reconnect each of the instrument panel wire harness connectors. Refer to Connector Locations for the location of more information on the instrument panel wire harness connector locations. 6. Install the instrument panel assembly onto the dash panel. Refer to Instrument Panel Assembly for the location of the instrument panel assembly installation procedures. 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Locations Ignition Off-Draw (IOD) Fuse: Locations The IOD fuse is located in the junction block. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Locations > Page 5480 Ignition Off-Draw (IOD) Fuse: Description and Operation IGNITION-OFF DRAW FUSE All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is removed when the vehicle is shipped from the factory. This fuse feeds various accessories that require battery current when the ignition switch is in the OFF position, including the clock. The IOD fuse is removed to prevent battery discharge during vehicle storage. When removing or installing the IOD fuse, it is important that the ignition switch be in the OFF position. Failure to place the ignition switch in the OFF position can cause the radio display to become scram- bled when the IOD fuse is removed and replaced. Removing and replacing the IOD fuse again, with the ignition switch in the OFF position, will correct the scrambled display condition. The IOD fuse should be checked if the radio or clock displays are inoperative. The IOD fuse is located in the junction block. Refer to the fuse layout label on the back of the instrument panel fuse access panel for IOD fuse identification and location. Fig. 3 Ignition-Off Draw Fuse - Typical IOD FUSE All vehicles are equipped with an Ignition-Off Draw (IOD) fuse (Fig. 3) that is disconnected within the Junction Block (JB) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the JB as part of the preparation procedures performed just prior to new vehicle delivery. The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed to provide service access to the fuses in the JB. A finger recess is molded into the access panel for easy removal. An adhesive-backed fuse layout map is secured to the instrument panel side of the access panel to ensure proper fuse identification. The IOD fuse is a 15 ampere mini blade-type fuse. The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in its JB cavity, and as a fuse holder that conveniently stores the fuse in the same JB cavity after it has been disconnected. The term ignition-off draw identifies a normal condition where power is being drained from the battery with the ignition switch in the OFF position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the OFF position, including the clock. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from JB fuse cavity 12 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse serves no useful purpose to the dealer technician in the service or diagnosis of any vehicle system or condition, other than the same purpose as that of any other standard circuit protection device. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Locations > Page 5481 The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Refer to Battery for the location of additional service information covering the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Locations > Page 5482 Ignition Off-Draw (IOD) Fuse: Testing and Inspection Ignition-Off Draw Test The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the OFF position. A normal vehicle electrical system will draw from five to thirty-five milliamperes (0.005 to 0.035 ampere) with the ignition switch in the OFF position, and all non-ignition controlled circuits in proper working order. Up to thirty-five milliamperes are needed to enable the memory functions for the Powertrain Control Module (PCM), digital clock, electronically tuned radio, and other modules which may vary with the vehicle equipment. A vehicle that has not been operated for approximately twenty days, may discharge the battery to an inadequate level. When a vehicle will not be used for twenty days or more (stored), remove the IOD fuse from the Power Distribution Center (PDC). This will reduce battery discharging. Excessive IOD can be caused by: - Electrical items left ON. - Faulty or improperly adjusted switches. - Faulty or shorted electronic modules and components. - An internally shorted generator. - Intermittent shorts in the wiring. If the IOD is over thirty-five milliamperes, the problem must be found and corrected before replacing a battery. In most cases, the battery can be charged and returned to service after the excessive IOD condition has been corrected. Electronic Module Ignition-Off-Draw (IOD) Table 1. Verify that all electrical accessories are OFF. Turn OFF all lamps, remove the ignition key, and close all doors. If the vehicle is equipped with an illuminated entry system or an electronically tuned radio, allow the electronic timer function of these systems to automatically shut off (time out). This may take up to three minutes. See the Electronic Module Ignition-Off Draw Table for more information. 2. Determine that the underhood lamp is operating properly, then disconnect the lamp wire harness connector or remove the lamp bulb. 3. Disconnect the battery negative cable. 4. Set an electronic digital multi-meter to its highest amperage scale. Connect the multi-meter between the disconnected battery negative cable terminal clamp and the battery negative terminal post. Make sure that the doors remain closed so that the illuminated entry system is not activated. The multi-meter amperage reading may remain high for up to three minutes, or may not give any reading at all while set in the highest amperage scale, depending upon the electrical equipment in the vehicle. The multi-meter leads must be securely clamped to the battery negative cable terminal clamp and the battery negative terminal post. If continuity between the battery negative terminal post and the negative cable terminal clamp is lost during any part of the IOD test, the electronic timer function will be activated and all of the tests will have to be repeated. 5. After about three minutes, the high-amperage IOD reading on the multi-meter should become very low or nonexistent, depending upon the electrical equipment in the vehicle. If the amperage reading remains high, remove and replace each fuse or circuit breaker in the Power Distribution Center (PDC) and then in the Junction Block (JB), one at a time until the amperage reading becomes very low, or nonexistent. This will isolate each circuit and identify the circuit that is the source of the high-amperage IOD. If the amperage reading remains high after removing and replacing each fuse and circuit breaker, disconnect the wire harness from the generator. If the amperage reading now becomes very low or nonexistent, refer to Charging System for the proper charging system diagnosis and testing procedures. After the high-amperage IOD has been corrected, switch the multi-meter to progressively lower amperage scales and, if necessary, repeat the fuse and circuit breaker remove-and-replace process to identify and correct all sources of excessive IOD. It is now safe to select the lowest milliampere scale of the multi-meter to check the low- amperage IOD. CAUTION: Do not open any doors, or turn ON any electrical accessories with the lowest milliampere scale selected, or the multi-meter may be Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Locations > Page 5483 damaged. 6. Observe the multi-meter reading. The low-amperage IOD should not exceed thirty-five milliamperes (0.035 ampere). If the current draw exceeds thirty-five milliamperes, isolate each circuit using the fuse and circuit breaker remove-and-replace process in Step 5. The multi-meter reading will drop to within the acceptable limit when the source of the excessive current draw is disconnected. Repair this circuit as required; whether a wiring short, incorrect switch adjustment, or a component failure is at fault. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Locations > Page 5484 Ignition Off-Draw (IOD) Fuse: Service and Repair Fig. 4 Ignition-Off Draw Fuse - Typical REMOVAL The Ignition-Off Draw (IOD) fuse is disconnected from Junction Block (JB) fuse cavity 12 (Fig. 4) when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. NOTE: When removing or installing the IOD fuse, it is important that the ignition switch be in the OFF position. Failure to place the ignition switch in the OFF position can cause the radio display to become scrambled when the IOD fuse is installed. Removing and installing the IOD fuse again with the ignition switch in the Oft position will usually correct the scrambled radio display condition. 1. Turn the ignition switch to the OFF position. 2. Remove the fuse access panel by unsnapping it from the left outboard end of the instrument panel. 3. Grasp the upper and lower tabs of the IOD fuse holder unit in fuse cavity 12 of the JB between the thumb and forefinger and pull the unit firmly outward. 4. Install the fuse access panel by snapping it onto the left outboard end of the instrument panel. INSTALLATION The Ignition-Off Draw (IOD) fuse is disconnected from Junction Block (JB) fuse cavity 12 (Fig. 4) when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. 1. Turn the ignition switch to the OFF position. 2. Remove the fuse access panel by unsnapping it from the left outboard end of the instrument panel. 3. To install the IOD fuse, use a thumb to press the IOD fuse holder unit in fuse cavity 12 firmly into the JB. 4. Install the fuse access panel by snapping it onto the left outboard end of the instrument panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > F42 > Oct > 06 > Recall - Potential Interior Fire Technical Service Bulletin # F42 Date: 061001 Recall - Potential Interior Fire October 2006 Dealer Service Instructions for: Safety Recall F42 Unused Wiring Connector Models 2001-2003 (DN) Dodge Durango NOTE: This recall applies only to the above vehicles equipped with a 40/20/40 bench seat (sales code CBE). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject An unused wiring connector under the front seat on about 34,900 of the above vehicles may become contaminated with spilled fluid and/or debris. This may cause a short circuit, which can result in an interior fire. Repair The unused connector under the front seat must be inspected for corrosion/debris and cleaned as necessary. In addition, a connector seal with a plastic retainer clip must be installed on the unused connector. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > F42 > Oct > 06 > Recall - Potential Interior Fire > Page 5493 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > F42 > Oct > 06 > Recall - Potential Interior Fire > Page 5494 Use the labor operation number and time allowance shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure 1. Open the driver's door and move the driver's seat to the full rearward position. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > F42 > Oct > 06 > Recall - Potential Interior Fire > Page 5495 2. Locate the unused electrical connector under the driver's seat near the transmission tunnel (Figure 1). NOTE: If the male side of the unused connector is missing, order male connector CBDPF422 for 2001 model year vehicles or CBDPF423 for 2002/2003 model year vehicles. 3. Slide the red locking tab towards the driver's side of the vehicle to release the primary lock on the connector. 4. Squeeze the tail end of the male connector to release the secondary connector lock and pull the connector apart. 5. Inspect the wiring harness side of the connector for corrosion and/or debris. If corrosion and/or debris is found, use Electrolyte Detection and Neutralizing Spray (P/N CBEJD201) to clean the corrosion and/or debris from the connector. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > F42 > Oct > 06 > Recall - Potential Interior Fire > Page 5496 6. Install the connector end seal, retainer cap and cavity plugs into the empty male connector (removed in Step 4) as shown in Figure 2. 7. Install the male connector onto the unused wiring harness connector and engage the red lock tab by sliding the lock tab towards the passenger side of the vehicle (Figure 2). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > F42 > Oct > 06 > Recall - Potential Interior Fire > Page 5497 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > NHTSA06V339000 > Sep > 06 > Recall 06V339000: Console Wiring Connector Modification Wiring Harness: Recalls Recall 06V339000: Console Wiring Connector Modification MAKE/MODELS: MODEL/BUILD YEARS: Dodge/Durango 2001-2003 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 06V339000 MFG'S REPORT DATE: September 06, 2006 COMPONENT: Electrical System POTENTIAL NUMBER OF UNITS AFFECTED: 35103 SUMMARY: On certain sport utility vehicles equipped with front bench seats only, if fluid is spilled from the floor mounted cup holder, an unused console power outlet connector located under the seat may become contaminated. CONSEQUENCE: This may allow development of a high resistive short circuit in the connector, which could eventually lead to a fire. REMEDY: Dealers will inspect the console wiring connector for corrosion, clean as required, and install a cap to prevent additional fluid from contaminating the connector free of charge. The manufacturer has not yet provided an owner notification schedule. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. F42. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > F42 > Oct > 06 > Recall - Potential Interior Fire Technical Service Bulletin # F42 Date: 061001 Recall - Potential Interior Fire October 2006 Dealer Service Instructions for: Safety Recall F42 Unused Wiring Connector Models 2001-2003 (DN) Dodge Durango NOTE: This recall applies only to the above vehicles equipped with a 40/20/40 bench seat (sales code CBE). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject An unused wiring connector under the front seat on about 34,900 of the above vehicles may become contaminated with spilled fluid and/or debris. This may cause a short circuit, which can result in an interior fire. Repair The unused connector under the front seat must be inspected for corrosion/debris and cleaned as necessary. In addition, a connector seal with a plastic retainer clip must be installed on the unused connector. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > F42 > Oct > 06 > Recall - Potential Interior Fire > Page 5507 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > F42 > Oct > 06 > Recall - Potential Interior Fire > Page 5508 Use the labor operation number and time allowance shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure 1. Open the driver's door and move the driver's seat to the full rearward position. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > F42 > Oct > 06 > Recall - Potential Interior Fire > Page 5509 2. Locate the unused electrical connector under the driver's seat near the transmission tunnel (Figure 1). NOTE: If the male side of the unused connector is missing, order male connector CBDPF422 for 2001 model year vehicles or CBDPF423 for 2002/2003 model year vehicles. 3. Slide the red locking tab towards the driver's side of the vehicle to release the primary lock on the connector. 4. Squeeze the tail end of the male connector to release the secondary connector lock and pull the connector apart. 5. Inspect the wiring harness side of the connector for corrosion and/or debris. If corrosion and/or debris is found, use Electrolyte Detection and Neutralizing Spray (P/N CBEJD201) to clean the corrosion and/or debris from the connector. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > F42 > Oct > 06 > Recall - Potential Interior Fire > Page 5510 6. Install the connector end seal, retainer cap and cavity plugs into the empty male connector (removed in Step 4) as shown in Figure 2. 7. Install the male connector onto the unused wiring harness connector and engage the red lock tab by sliding the lock tab towards the passenger side of the vehicle (Figure 2). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > F42 > Oct > 06 > Recall - Potential Interior Fire > Page 5511 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > NHTSA06V339000 > Sep > 06 > Recall 06V339000: Console Wiring Connector Modification Wiring Harness: All Technical Service Bulletins Recall 06V339000: Console Wiring Connector Modification MAKE/MODELS: MODEL/BUILD YEARS: Dodge/Durango 2001-2003 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 06V339000 MFG'S REPORT DATE: September 06, 2006 COMPONENT: Electrical System POTENTIAL NUMBER OF UNITS AFFECTED: 35103 SUMMARY: On certain sport utility vehicles equipped with front bench seats only, if fluid is spilled from the floor mounted cup holder, an unused console power outlet connector located under the seat may become contaminated. CONSEQUENCE: This may allow development of a high resistive short circuit in the connector, which could eventually lead to a fire. REMEDY: Dealers will inspect the console wiring connector for corrosion, clean as required, and install a cap to prevent additional fluid from contaminating the connector free of charge. The manufacturer has not yet provided an owner notification schedule. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. F42. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications Alignment: Specifications NOTE: All alignment specifications are in degrees. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 5520 Alignment: Description and Operation DESCRIPTION Wheel alignment involves the correct positioning of the wheels in relation to the vehicle. The positioning is accomplished through suspension and steering linkage adjustments. An alignment is considered essential for efficient steering, good directional stability and to minimize tire wear. The most important measurements of an alignment are caster, camber and toe. CAUTION: Never attempt to modify suspension or steering components by heating or bending. NOTE: Periodic lubrication of the front suspension/steering system components may be required. Rubber bushings must never be lubricated. OPERATION - CASTER is the forward or rearward tilt of the steering knuckle from vertical. Tilting the top of the knuckle forward provides negative caster. Tilting the top of the knuckle rearward provides positive caster. Positive caster promotes directional stability. This angle enables the front wheels to return to a straight ahead position after turns. - CAMBER is the inward or outward tilt of the wheel relative to the center of the vehicle. Tilting the top of the wheel inward provides negative camber. Tilting the top of the wheel outward provides positive camber. Incorrect camber will cause wear on the inside or outside edge of the tire. - TOE is the difference between the leading inside edges and trailing inside edges of the front tires. wheel position out of specification cause's unstable steering, uneven tire wear and steering wheel off center. The wheel toe position is the final front wheel alignment adjustment. - THRUST ANGLE is the angle of the rear axle relative to the centerline of the vehicle. Incorrect thrust angle can cause off-center steering and excessive tire wear. This angle is not adjustable, damaged component(s) must be replaced to correct the thrust angle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Pre-Alignment Inspection Alignment: Service and Repair Pre-Alignment Inspection DIAGNOSIS AND TESTING - PRE-ALIGNMENT INSPECTION Before starting wheel alignment, the following inspection and necessary corrections must be completed. 1. Inspect tires for size, air pressure and tread wear. 2. Inspect front wheel bearings for wear. 3. Inspect front wheels for excessive radial or lateral runout and balance. 4. Inspect ball studs, linkage pivot points and steering gear for looseness, roughness or binding. 5. Inspect suspension components for wear and noise. 6. On 4x4 vehicles check suspension height. 7. Road test the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 5523 Alignment: Service and Repair Wheel Alignment STANDARD PROCEDURE - HEIGHT MEASUREMENT The vehicle suspension height should be measured and adjusted if necessary before performing wheel alignment procedure. Also when front suspension components have been replaced. This measure must be performed with the vehicle supporting it's own weight and taken on both sides of the vehicle. 1. Jounce the front of the vehicle. 2. Measure and record the distance between the ground and the center of the lower suspension arm rear mounting bolt head. 3. Measure and record the distance between the ground and the center of the front wheel. 4. Subtract the first measurement from the second measurement. The difference between the two measurement should be 73 mm (2.9 inches) + 3 mm (0.12 inches). STANDARD PROCEDURE- HEIGHT ADJUSTMENT The vehicle suspension height should be measured and adjusted if necessary before performing wheel alignment procedure. Also when front suspension components have been replaced. This measure must be performed with the vehicle supporting it's own weight and taken on both sides of the vehicle. To adjust the vehicle height turn the torsion bar adjustment bolt CLOCKWISE to raise the vehicle and COUNTER CLOCKWISE to lower the vehicle. CAUTION: ALWAYS raise the vehicle to the correct suspension height, NEVER lower the vehicle to obtain the correct suspension height. If the vehicle suspension height is too high, lower the vehicle below the height specification. Then raise the vehicle to the correct suspension height specification. This will insure the vehicle maintains the proper suspension height. NOTE: If a height adjustment has been made, perform height measurement again on both sides of the vehicle. STANDARD PROCEDURE - CAMBER AND CASTER ADJUSTMENT Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 5524 Camber and caster angle adjustments involve changing the position of the upper suspension arm pivot bar. NOTE: On 4x2 vehicles use Alignment Tool 8393 for alignment. The tool attaches to the pivot bar on the upper control arm. STANDARD PROCEDURE- CASTER Moving the rear position of the pivot bar in or out, will change the caster angle significantly and camber angle only slightly. To maintain the camber angle while adjusting caster, move the rear of the pivot bar in or out. Then move the front of the pivot bar slightly in the opposite direction. To increase positive caster angle, move the rear position of the pivot bar inward (toward the engine). Move the front of pivot bar outward (away from the engine) slightly until the original camber angle is obtained. STANDARD PROCEDURE - CAMBER Move the front of the pivot bar in or out. This will change the camber angle significantly and caster angle slightly. After adjustment is made tighten the pivot bar nuts to proper torque specification. STANDARD PROCEDURE - TOE ADJUSTMENT The wheel toe position adjustment is the final adjustment. 1. Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheel with the front wheels in the straight-ahead position. 2. Loosen the tie rod jam nuts. NOTE: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straight-ahead. 3. Adjust the wheel toe position by turning the tie rod as necessary. 4. Tighten the tie rod jam nut to 75 Nm (55 ft. lbs.). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 5525 5. Verify the specifications 6. Turn oh engine. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications Power Steering Pressure Switch: Specifications Power Steering Pressure Switch ............................................................................................................................................... 14-22 Nm (124-195 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 5531 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 5532 Power Steering Pressure Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 5533 Power Steering Pressure Switch: Description and Operation DESCRIPTION A pressure sensing switch is included in the power steering system (mounted on the high pressure line). This switch will be used only on vehicles equipped with a 4.7L V-8 engine and power steering. OPERATION The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high pump load and low engine rpm; such as during parking maneuvers. The PCM will then increase the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load. When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the normally closed switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling. When pump pressure drops to approximately 1379 kPa (200 psi), the switch circuit will re-close and engine idle speed will return to its previous setting. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 5534 Power Steering Pressure Switch: Service and Repair REMOVAL The power steering pressure switch is installed in the power steering high-pressure hose. 1. Disconnect electrical connector from power steering pressure switch. 2. Place a small container or shop towel beneath switch to collect any excess fluid. 3. Remove switch. Use back-up wrench on power steering line to prevent line bending. INSTALLATION This switch is used only with 4.7L V-8 engine. 1. Install power steering switch into power steering line. 2. Tighten to 14-22 Nm (124-195 inch lbs.) torque. 3. Connect electrical connector to switch. 4. Check power steering fluid and add as necessary. 5. Start engine and again check power steering fluid. Add fluid if necessary. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Description and Operation Front Steering Knuckle: Description and Operation DESCRIPTION The knuckle is a single casting with legs machined for the upper and lower ball joints. The knuckle also has machined mounting locations for the front brake calipers and hub bearing. OPERATION The steering knuckle pivot between the upper and lower ball joint. Steering linkage attached to the knuckle allows the vehicle to be steered. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Description and Operation > Page 5539 Front Steering Knuckle: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove disc brake caliper, rotor, shield and ABS speed sensor. 4. Remove tie-rod from steering knuckle arm. 5. Remove the hub/bearing. 6. Remove the shock absorber. 7. Install Spring Compressor DD-1278 up through the lower suspension arm, coil spring and upper shock mounting hole. 8. Tighten the tool lower nut to compress the coil spring. 9. Remove the lower ball joint nut and separate the ball joint from the knuckle with Remover C-4150A. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Description and Operation > Page 5540 10. Remove the upper ball joint nut and separate the ball joint from the knuckle with Remover MB-991113. CAUTION: When install Remover MB-991113 to separate the ball joint, be careful not to damage the ball joint seal. 11. Remove steering knuckle. INSTALLATION 1. Position steering knuckle on upper and lower ball joints and install nuts. Tighten lower nut to 127 Nm (94 ft. lbs.). Tighten upper nut to 81 Nm (60 ft. lbs.) and install new cotter pins. 2. Remove the spring compressor. 3. Install the shock absorber. 4. Install the hub/bearing. 5. Install ADS speed sensor, brake dust shield, rotor and caliper. 6. Install tie rod to steering knuckle arm. 7. Install the wheel and tire assembly. 8. Remove support and lower the vehicle Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 5546 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 5547 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 5548 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 5549 Power Steering Fluid: Specifications All models Mopar Power Steering Fluid or equivalent Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 5550 Power Steering Fluid: Service Precautions DO NOT use automatic transmission fluid instead of Mopar Power Steering Fluid. System damage can result. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair Power Steering Fluid Cooler: Service and Repair FLUID COOLER REMOVAL 1. Siphon the power steering system. 2. Disconnect the return hose at the pump. 3. Raise and support the vehicle. 4. Disconnect the return hose at the cooler. 5. Remove the cooler mounting nut and bolt. 6. Remove the cooler. INSTALLATION 1. Install the cooler. 2. Install the cooler mounting nut and bolt. 3. Reconnect the return hose at the cooler. 4. Remove the support and lower the vehicle. 5. Reconnect the return hose at the pump. 6. Refill the power steering system. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Power Steering Line Pressure Line 25 ft.lb Return Line 25 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Pressure Power Steering Line/Hose: Service and Repair Hose - Pressure REMOVAL - PRESSURE HOSE 1. Siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the pressure hose at the pump. 4. Disconnect the pressure hose at the gear. 5. Remove the pressure hose from the vehicle. INSTALLATION - PRESSURE HOSE 1. Install the pressure hose to the vehicle. 2. Reconnect the pressure hose at the gear. Tighten the hose to 34 Nm (25 ft. lbs.). 3. Reconnect the pressure hose at the pump. Tighten the hose to 34 Nm (25 ft. lbs.). 4. Remove the support and lower the vehicle. 5. Refill the power steering system. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Pressure > Page 5559 Power Steering Line/Hose: Service and Repair Hose - Return REMOVAL - RETURN HOSE 1. Siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the return hose at the cooler. 4. Disconnect the return hose at the gear. 5. Remove the return hose from the vehicle. INSTALLATION - RETURN HOSE 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. Tighten the hose to 34 Nm (25 ft. lbs.). 3. Reconnect the return hose at the gear. Tighten the hose to 34 Nm (25 ft. lbs.). 4. Remove the support and lower the vehicle. 5. Refill the power steering system. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 5564 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 5565 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 5566 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 5569 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 5570 Power Steering Pump: Description and Operation DESCRIPTION The pump is connected to the steering gear via the pressure hose and the return hose. The pump shaft has a pressed-on pulley that is belt driven by the crankshaft pulley. Trailer tow option vehicles are equipped with a power steering pump oil cooler. On the 5.9L the oil cooler is mounted to the engine block. On the 4.7L the oil cooler is mounted to the power steering pump. NOTE: Power steering pumps are not interchangeable with pumps installed on other vehicles. OPERATION Hydraulic pressure is provided for the power steering gear by the belt driven power steering pump and. The power steering pumps are constant flow rate and displacement, vane-type pumps. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 5571 Power Steering Pump: Testing and Inspection DIAGNOSIS AND TESTING - PUMP LEAKAGE The pump is serviced as an assembly and should not be disassembled. Plastic pump reservoirs can be replace and the reservoir O-ring. Check for leaks in the following areas: Pump shaft seal behind the pulley - Pump to reservoir O-ring - Reservoir cap - Pressure and return lines - Flow control valve fitting Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Power Steering Pump: Service and Repair Power Steering Pump Initial Operation STANDARD PROCEDURE - POWER STEERING PUMP INITIAL OPERATION WARNING: THE FLUID LEVEL SHOULD BE CHECKED WITH ENGINE OFF TO PREVENT INJURY FROM MOVING COMPONENTS. CAUTION: Use MOPAR Power Steering Fluid or equivalent. Do not use automatic transmission fluid and do not overfill. Wipe filler cap clean, then check the fluid level. The dipstick should indicate COLD when the fluid is at normal temperature. 1. Turn steering wheel all the way to the left 2. Fill the pump fluid reservoir to the proper level and let the fluid settle for at least two 2 minutes. 3. Raise the front wheels off the ground. 4. Slowly turn the steering wheel lock-to-lock 20 times with the engine off while checking the fluid level. NOTE: Vehicles with long return lines or oil coolers turn wheel 40 times. 5. Start the engine. With the engine idling maintain the fluid level. 6. Lower the front wheels and let the engine idle for two minutes. 7. Turn the steering wheel in both direction and verify power assist and quiet operation of the pump. If the fluid is extremely foamy or milky looking, allow the vehicle to stand a few minutes and repeat the procedure. CAUTION: Do not run a vehicle with foamy fluid for an extended period. This may cause pump damage. Removal and Installation REMOVAL 1. Remove the serpentine drive belt. 2. Remove return hose from the pump reservoir and drain the pump. 3. Remove power steering pressure switch connector and remove pressure line from the bottom of the pump. 4. Remove the oil cooler mounting bolt from the pump bracket if equipped. a. Remove 3 pump mounting bolts through pulley access holes. INSTALLATION 1. Align the pump with the mounting holes in the left cylinder head. 2. Install 3 pump mounting bolts through the pulley access holes. Tighten the bolts to 28 Nm (21 ft. lbs.). 3. Install the oil cooler to the pump bracket if equipped. Install the oil cooler mounting bolt. 4. Install the pressure line and return hose to the pump. Tighten the pressure line to 35 Nm (25 ft. lbs.). 5. Install power steering pressure switch connector. 6. Install the serpentine drive belt. 7. Fill the power steering pump and perform Power Steering Pump Initial Operation. See: Initial Operation Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 5574 Power Steering Pump: Service and Repair Power Steering Pump Pulley REMOVAL CAUTION: On vehicles equipped with the 4.7L, Do not reuse the old power steering pump pulley it is not intended for reuse. A new pulley must be installed if removed. 1. Remove pump assembly. 2. Remove pulley from pump with Puller C-4333. INSTALLATION CAUTION: On vehicles equipped with the 4.7L, Do not reuse the old power steering pump pulley it is not intended for reuse. A new pulley must be installed if removed. 1. Replace pulley if bent, cracked, or loose. 2. Install pulley on pump with Installer C-4063-B flush with the end of the shaft. Ensure the tool and pulley remain aligned with the pump shaft. 3. Install pump assembly. 4. With Serpentine Belts; Run engine until warm (5 min) and note any belt chirp. If chirp exists, move pulley outward approximately 0.5 mm (0.020 inch). If noise increases, press on 1.0 mm (0.040 inch). Be careful that pulley does not contact mounting bolts. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Page 5575 Power Steering Pump: Tools and Equipment POWER STEERING PUMP Analyzer Set, Power Steering Flow/Pressure 6815 Adapters, Power Steering Flow/Pressure Tester 6893 Puller C-4333 Installer, Power Steering pulley C-4063-B Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications Power Steering Pressure Switch: Specifications Power Steering Pressure Switch ............................................................................................................................................... 14-22 Nm (124-195 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 5580 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 5581 Power Steering Pressure Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 5582 Power Steering Pressure Switch: Description and Operation DESCRIPTION A pressure sensing switch is included in the power steering system (mounted on the high pressure line). This switch will be used only on vehicles equipped with a 4.7L V-8 engine and power steering. OPERATION The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high pump load and low engine rpm; such as during parking maneuvers. The PCM will then increase the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load. When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the normally closed switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling. When pump pressure drops to approximately 1379 kPa (200 psi), the switch circuit will re-close and engine idle speed will return to its previous setting. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 5583 Power Steering Pressure Switch: Service and Repair REMOVAL The power steering pressure switch is installed in the power steering high-pressure hose. 1. Disconnect electrical connector from power steering pressure switch. 2. Place a small container or shop towel beneath switch to collect any excess fluid. 3. Remove switch. Use back-up wrench on power steering line to prevent line bending. INSTALLATION This switch is used only with 4.7L V-8 engine. 1. Install power steering switch into power steering line. 2. Tighten to 14-22 Nm (124-195 inch lbs.) torque. 3. Connect electrical connector to switch. 4. Check power steering fluid and add as necessary. 5. Start engine and again check power steering fluid. Add fluid if necessary. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 5588 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair Steering Column Cover: Service and Repair STEERING COLUMN OPENING COVER REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Fig. 14 2. Reach under the left end of the instrument panel to access and unsnap the rod end clip on the park brake release link and disengage the link from the back of the handle (Fig. 14). 3. Remove the three screws that secure the lower edge of the steering column opening cover to the instrument panel structural support. Fig. 15 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Page 5592 4. Using a trim stick C-4755 or equivalent, gently pry the upper edge of the steering column opening cover just below the cluster bezel on each side of the steering column away from the instrument panel far enough to disengage each of the snap clip retainers from their receptacles in the instrument panel base trim (Fig. 15). 5. Remove the steering column opening cover from the instrument panel. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the steering column opening cover to the instrument panel (Fig. 15). 2. Align the snap clip retainers on the steering column opening cover with the receptacles in the instrument panel base trim. 3. Using hand pressure, press firmly on the steering column opening cover over the snap clip locations until each of the snap clips is fully engaged in its receptacle. 4. Install the three screws that secure the lower edge of the steering column opening cover to the instrument structural support (Fig. 14). 5. Reach under the left end of the instrument panel to access and engage the park brake release link to the back of the handle. Then snap the rod end clip over the park brake release link to secure the connection. 6. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 5596 Steering Gear: Description and Operation DESCRIPTION A rack and pinion steering gears is made up of two main components, the pinion shaft and the rack. The gear cannot be adjusted or internally serviced. If a malfunction or a fluid leak occurs, the gear must be replaced as an assembly. OPERATION The steering column shaft is attached to the gear pinion. The rotation of the pinion moves the gear rack from side-to-side. This lateral action of the rack pushes and pulls the tie rods to change the direction of the front wheels. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 5597 Steering Gear: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Remove the nuts from the tie rod ends. 3. Separate tie rod ends from the knuckles with Puller C-3894-A. 4. Remove the power steering lines from the gear. 5. Remove the lower coupler bolt and slide the coupler off the gear. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 5598 6. Remove the mounting bolts from the gear to the front crossmember and remove the gear. INSTALLATION NOTE: Before installing gear inspect bushings and replace if worn or damaged. 1. Install gear on front crossmember and tighten mounting bolts to 258 Nm (190 ft. lbs.). 2. Slide shaft coupler onto gear. Install new bolt and tighten to 49 Nm (36 ft. lbs.). 3. Clean tie rod end studs and knuckle tapers. 4. Install tie rod ends into the steering knuckles and tighten the nuts to 108 Nm (80 ft. lbs.). 5. Install power steering lines to steering gear. 6. Remove support and lower vehicle. 7. Fill power steering system. 8. Adjust the toe position. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 5599 Steering Gear: Tools and Equipment RACK AND PINION STEERING GEAR Puller C-3894-A Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications Tie Rod End: Specifications Tie Rod End Knuckle Nut 80 ft.lb Jam Nut 55 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications > Page 5604 Tie Rod End: Description and Operation BOOT SEAL DESCRIPTION The boot seal is a bellows type seal the protects dirt and contaminates from entering the open gears of the rack and pinion unit. OPERATION The boot seal operates with the inward and outward motions of the rack and pinion, If the seal is worn or ripped in any way it must be replaced. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner Tie Rod End Tie Rod End: Service and Repair Inner Tie Rod End REMOVAL - INNER TIE ROD END 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly. 3. Remove the outer tie rod end. 4. Remove the boot seal. 5. Remove the inner tie rod end from the rack INSTALLATION - INNER TIE ROD END NOTE: Do not twist the boot at anytime during installation. 1. Thread the inner tie rod end into the rack and pinion. 2. Tighten the inner tie to 68 Nm (50 ft. lbs.). 3. Install the boot seal. 4. Install the out tie rod end. 5. Install the tire and wheel assembly. 6. Remove the support and lower the vehicle. 7. Set wheel toe pattern. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner Tie Rod End > Page 5607 Tie Rod End: Service and Repair Outer Tie Rod End REMOVAL - OUTER TIE ROD END NOTE: Do not twist the boot at anytime during removal or installation. 1. Loosen the jam nut. 2. Remove the outer tie rod end nut at the steering knuckle. 3. Separate the tie rod ball stud from the knuckle with Remover MB-991113. 4. Unthread the outer tie rod end from the inner tie rod. INSTALLATION - OUTER TIE ROD END NOTE: Do not twist the boot at anytime during removal or installation. 1. Thread the outer tie rod end onto the inner tie rod, to it's original position. 2. Install the outer tie rod end into the steering knuckle. 3. Tighten the ball stud nut on the steering knuckle to 88 Nm (65 ft. lbs.). 4. Tighten jam nut to 75 Nm (55 ft. lbs.). 5. Set wheel toe pattern. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner Tie Rod End > Page 5608 Tie Rod End: Service and Repair Tie Rod End Dust Cover REMOVAL 1. Loosen the jam nut to remove the outer tie rod end. 2. Remove the jam nut. 3. Remove the outer clamp from the rubber boot. 4. Remove the boot inner clamp. 5. On 4x2 vehicles mark the breather tube location on steering gear before removing the rubber boot INSTALLATION 1. Lubricate the boot outer groove (tie rod) with silicone type lubricant. Ensure that the boot is not twisted. 2. On 4x2 vehicles align the breather tube with the reference mark on the steering gear. 3. Position and align the new boot over the housing. 4. Install inner clamp on the rubber boot. 5. Install the snorkel clamp on 4x2 vehicles. 6. Install outer clamp on the inner tie rod. 7. Install the jam nut and the outer tie rod end. 8. Perform a wheel alignment. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Suspension - Upper Ball Joint Replacement/Warranty Ext. Ball Joint: Technical Service Bulletins Suspension - Upper Ball Joint Replacement/Warranty Ext. NUMBER: 02-010-04 GROUP: Suspension DATE: December 16, 2004 SUBJECT: Upper Ball Joint Extended Warranty OVERVIEW: This bulletin involves inspecting and if necessary replacing the upper ball joints. NOTE: The upper ball joint warranty period has been extended to 10 years or 100,000 miles. Refer to Warranty Bulletin D-04-34 for complete details. MODELS: 2000 - 2003 (AN) Dakota 4x2 2000 - 2003 (DN) Durango 4x2 NOTE: This bulletin applies only to the above vehicles built through December 31, 2002 (MDH 1231XX). DIAGNOSIS: 1. Position a floor jack under the right side lower suspension arm. 2. Raise the wheel and allow the tire to lightly contact the floor (vehicle weight relieved from the tire). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Suspension - Upper Ball Joint Replacement/Warranty Ext. > Page 5614 3. Mount a dial indicator (Special Tool C3339 or equivalent) solidly on the upper suspension arm (Fig. 1). 4. Position the dial indicator plunger against the back side of the steering knuckle boss for the upper ball joint (Fig. 1). 5. Zero the dial indicator while pulling outward on the top of the tire. 6. While an assistant watches the dial indicator gauge, grasp the top of the tire and push inward. Record the dial indicator reading observed from the full outward to full inward position. 7. Repeat Step #1 through Step # 6 on the left side upper ball joint. When both the left and the right upper ball joints have been inspected, proceed to Step # 8. 8. Based on the results recorded in Step # 6: a. If the lateral movement on both upper ball joints is less than 0.060 in. (1.52 mm), no further action is required. Remove the dial indicator, lower the wheel and return the vehicle to the owner. b. If the lateral movement on either of the upper ball joints is greater than 0.060 in. (1.52 mm), replace both upper ball joints as described in the Repair Procedure. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Suspension - Upper Ball Joint Replacement/Warranty Ext. > Page 5615 SPECIAL TOOLS/EQUIPMENT REQUIRED: PARTS REQUIRED: REPAIR PROCEDURE: 1. Raise the vehicle on an appropriate hoist. 2. Remove the front wheel and tire assemblies. 3. Position a hydraulic jack under the left side lower control arm and raise the jack to unload the rebound bumper. 4. Remove the cotter pin from the upper ball joint castle nut. 5. Remove the upper ball joint castle nut from the upper ball joint stud. 6. Using a die grinder equipped with a cut-off wheel, grind an "X" through each of the three upper ball joint rivet heads (Fig. 2). CAUTION: Do not grind into the control arm. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Suspension - Upper Ball Joint Replacement/Warranty Ext. > Page 5616 7. Using an air chisel, chisel the three rivet heads off of the upper ball joint. 8. Punch out the rivets using a drift and hammer. 9. Separate the upper ball joint from the steering knuckle with special tool MB991113. 10. Remove and discard the old ball joint. 11. Using 100 grit emery cloth, lightly sand the top surface of the steering knuckle to remove any rust and/or scale from the steering knuckle (Fig. 3). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Suspension - Upper Ball Joint Replacement/Warranty Ext. > Page 5617 12. Insert the bolts supplied with the ball joint package from the bottom side of the control arm (Fig. 4). 13. Place the new ball joint onto the control arm and install retaining nuts (Fig. 4). Tighten the nuts to 50 ft. lbs. (68 N.m). 14. Position the steering knuckle onto the upper ball joint stud. 15. Install the castle nut onto the ball joint stud. Tighten the upper ball joint castle nut to 60 ft. lbs. (81 N.m). NOTE: If the castle nut slots do not line up with the cotter pin hole in the ball joint stud, continue tightening the nut until the next set of castle nut slots line up with the cotter pin hole. Do not loosen the nut. 16. Install a new cotter pin through the castle nut and secure it by bending the arms of the pin. 17. Install the wheel and tire assembly. Tighten the lug nuts to 100 ft. lbs (135 N.m). 18. Repeat Step # 3 through Step # 17 on the right side of the vehicle. 19. Lower the vehicle. 20. Place the vehicle on an alignment rack and set toe to +0.10 degrees (+/- 0.06 degrees). POLICY: Reimbursable within the provisions of the extended warranty period of 10 years or 100,000 miles. Refer to Warranty Bulletin D-04-34 for complete details. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Page 5618 Ball Joint: Specifications Ball Joint Wear Limit ............................................................................................................................ ...................................................................... 0.060" Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 DIAGNOSIS AND TESTING - LOWER BALL JOINT 1. Raise the front of the vehicle. Place safety floor stands under both lower suspension arms as far outboard as possible. Lower the vehicle to allow the stands to support some or all of the vehicle weight. NOTE: The upper suspension arms must not contact the rebound bumpers. 2. Remove the tire and wheel assemblies. 3. Mount a dial indicator solidly under the lower suspension arm. 4. Position indicator plunger against the bottom of the steering knuckle lower ball joint boss. NOTE: The dial indicator plunger must be perpendicular to the machined surface of the steering knuckle lower ball joint boss. 5. Position a pry bar over the top of the upper suspension arm and under the pivot bar of the upper suspension arm. Pry down on the upper suspension arm and then zero the dial indicator. 6. Reposition the pry bar under the upper suspension arm and on top of the frame rail. Pry up on the upper suspension arm and record the dial indicator reading. 7. If the travel exceeds 1.52 mm (0.060 inch), replace the lower suspension arm. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Lower Ball Joint > Page 5621 Ball Joint: Testing and Inspection Upper Ball Joint DIAGNOSIS AND TESTING 1. Position a floor jack under the lower suspension arm. Raise the wheel and allow the tire to lightly contact the floor (vehicle weight relieved from the tire). 2. Mount a dial indicator solidly on the upper suspension arm. 3. Position the indicator plunger against the upper ball joint boss of the steering knuckle. 4. Grasp the top of the tire and apply force in and out. Look for movement at the ball joint between the upper suspension arm and steering knuckle. 5. If lateral movement is greater than 1.52 mm (0.060 inch), replace upper suspension arm. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair Control Arm Bushing: Service and Repair BUSHINGS - CONTROL ARM REMOVAL 1. Remove the control arm from the vehicle. 2. Mount the control arm securely in a vise. 3. Remove the nut and washer from the control arm shaft. 4. Install the bushing tool. 5. Press out the old bushings. INSTALLATION 1. Install the bushing in the control arm and inserted over the shaft. 2. Install the bushing tool. 3. Press the bushing into the control arm. 4. Install the washer and nut to the control arm shaft. Tighten the nut to 167 Nm (130 ft. lbs.). 5. Remove the control arm from the vise. 6. Install the control arm in the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Transmission Crossmember - Service Precautions Cross-Member: Technical Service Bulletins Transmission Crossmember - Service Precautions NUMBER: 13-002-00 GROUP: Frame And Bumpers DATE: Oct. 27, 2000 SUBJECT: Transmission Crossmember Service MODELS: 2000 - 2001 (AN) Dakota 2000 - 2001 (DN) Durango DISCUSSION: The fasteners that retain the transmission crossmember to the frame utilize a thread lock patch on the threads of the fastener. The thread lock patch is required to help prevent the fastener from loosening during normal vehicle usage. When the transmission crossmember is required to be removed during service, the amount of thread patch material on the fastener will deteriorate during fastener removal. To ensure that the fastener retention is not compromised after service, the transmission crossmember fastener threads must have Mopar Lock & Seal p/n 04318031 added to the threads of each fastener. POLICY: Information Only Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Description and Operation Front Steering Knuckle: Description and Operation DESCRIPTION The knuckle is a single casting with legs machined for the upper and lower ball joints. The knuckle also has machined mounting locations for the front brake calipers and hub bearing. OPERATION The steering knuckle pivot between the upper and lower ball joint. Steering linkage attached to the knuckle allows the vehicle to be steered. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Description and Operation > Page 5633 Front Steering Knuckle: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove disc brake caliper, rotor, shield and ABS speed sensor. 4. Remove tie-rod from steering knuckle arm. 5. Remove the hub/bearing. 6. Remove the shock absorber. 7. Install Spring Compressor DD-1278 up through the lower suspension arm, coil spring and upper shock mounting hole. 8. Tighten the tool lower nut to compress the coil spring. 9. Remove the lower ball joint nut and separate the ball joint from the knuckle with Remover C-4150A. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Description and Operation > Page 5634 10. Remove the upper ball joint nut and separate the ball joint from the knuckle with Remover MB-991113. CAUTION: When install Remover MB-991113 to separate the ball joint, be careful not to damage the ball joint seal. 11. Remove steering knuckle. INSTALLATION 1. Position steering knuckle on upper and lower ball joints and install nuts. Tighten lower nut to 127 Nm (94 ft. lbs.). Tighten upper nut to 81 Nm (60 ft. lbs.) and install new cotter pins. 2. Remove the spring compressor. 3. Install the shock absorber. 4. Install the hub/bearing. 5. Install ADS speed sensor, brake dust shield, rotor and caliper. 6. Install tie rod to steering knuckle arm. 7. Install the wheel and tire assembly. 8. Remove support and lower the vehicle Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Specifications > Front Stabilizer Bar: Specifications Stabilizer Bar Link Upper nut 27 ft.lb Link Ball Stud Nut 35 ft.lb Retainer Bolts 45 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Specifications > Front > Page 5639 Stabilizer Bar: Specifications Stabilizer Bar Link Upper Nut 70 ft.lb Link Lower Nut 50 ft.lb Retainer Bolts 40 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Description and Operation > Front Stabilizer Bar: Description and Operation Front DESCRIPTION The bar extends across the front underside of the chassis and mounts on the frame rails. Links connected the bar to the lower suspension arms. Stabilizer bar mounts are isolated by rubber bushings. Links are isolated with rubber grommets. OPERATION The stabilizer bar is used to minimize vehicle front sway during turns. The spring steel bar helps to control the vehicle body in relationship to the suspension. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Description and Operation > Front > Page 5642 Stabilizer Bar: Description and Operation Rear DESCRIPTION The stabilizer bar extends across the underside of the vehicle and is bolted to the top of the axle. Links at the end of the bar are bolted to the frame. OPERATION The stabilizer bar is used to minimize vehicle body roll. The spring steel bar helps to control the vehicle body in relationship to the suspension. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front Stabilizer Bar: Service and Repair Front REMOVAL 1. Raise and support the vehicle. 2. Remove the upper link nut, retainer and grommet from each link. 3. Remove the lower link nut from the lower suspension arm on each side. 4. Remove the stabilizer bar retainer bolts and remove the retainers and stabilizer bar from the vehicle. 5. Remove the bushings from the stabilizer bar. INSTALLATION 1. Install the bushings on the stabilizer bar. 2. Install the stabilizer bar on the frame and install the retainers and the bolts. 3. Tighten the bolts to 60 Nm (45 ft. lbs.). NOTE: Ensure the bar is center with equal spacing on both sides. 4. Install the link lower retainer and grommet on the links. 5. Install the links into the stabilizer bar and lower suspension arm on each side. 6. Install the lower link mounting nut and tighten to 47 Nm (35 ft. lbs.). NOTE: Ensure both link end caps are facing straight forward. 7. Install the upper link grommet, retainer and nut and tighten to 37 Nm (27 ft. lbs.). 8. Remove support and lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front > Page 5645 Stabilizer Bar: Service and Repair Rear REMOVAL 1. Raise and support vehicle. 2. Remove links upper mounting nuts arid bolts. 3. Remove the cotter pins and nuts from the links at the stabilizer bar. 4. Separate the links from the stabilizer bar with Puller C-3894-A and remove the links. 5. Remove stabilizer bar retainer bolts and retainers. 6. Remove stabilizer bar and remove bushings. INSTALLATION 1. Install stabilizer bar bushings. 2. Install the stabilizer bar and center it with equal spacing on both sides. 3. Install stabilizer bar retainers and tighten bolts to 54 Nm (40 ft. lbs.). 4. Install link on the frame and the stabilizer bar. Install mounting bolts and nuts. 5. Remove support and lower vehicle. 6. Tighten stabilizer link upper nuts to 95 Nm (70 ft. lbs.). 7. Tighten stabilizer link lower nuts to 68 Nm (50 ft. lbs.) and install a new cotter pins. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Specifications Suspension Spring ( Coil / Leaf ): Specifications Spring U-Bolt Nuts 90 ft.lb Spring Eye Nut 85 ft.lb Spring Shackle nut 85 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Coil Spring Suspension Spring ( Coil / Leaf ): Description and Operation Coil Spring DESCRIPTION The springs mount between the lower suspension arms and frame rail spring seats. A rubber isolator seats on top off the spring to help prevent noise. OPERATION The coil springs control ride quality and maintain proper ride height. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Coil Spring > Page 5651 Suspension Spring ( Coil / Leaf ): Description and Operation Leaf Spring DESCRIPTION The rear suspension system uses multi-leaf single stage springs and a solid drive axle. The forward end of the springs are mounted to the body rail hangers through rubber bushings. The rearward end of the springs are attached to the body by the use of shackles. The spring and shackles use rubber bushings. The bushing help to isolate road noise. OPERATION The springs control ride quality and maintain vehicle ride height. The shackles allow the springs to change their length as the vehicle moves over various road conditions. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Bushings Suspension Spring ( Coil / Leaf ): Service and Repair Bushings BUSHINGS REMOVAL 1. Remove the spring from the vehicle. 2. Position the spring eye in a press. 3. Press the bushing out with an appropriate size driver. INSTALLATION 1. Press new bushing into the spring eye with an appropriate size driver. The bushing should be centered in the spring eye. 2. Install the spring on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Bushings > Page 5654 Suspension Spring ( Coil / Leaf ): Service and Repair Coil Spring COIL SPRING REMOVAL 1. Raise and support the vehicle. 2. Remove wheel and tire assembly. 3. Remove the stabilizer bar link from the lower suspension arm. 4. Remove the shock absorber. 5. Install Spring Compressor DD-1278 up through the lower suspension arm, coil spring and upper shock mounting hole. 6. Tighten the tool lower nut to compress the coil spring. 7. Remove the lower ball joint nut and separate the ball joint from the knuckle with Remover C-4150A. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Bushings > Page 5655 8. Loosen the spring compressor lower nut to relieve spring tension. 9. Remove the tool and pull down on the lower suspension arm to remove the spring. INSTALLATION NOTE: The ramped or open end of the coil spring is the bottom of the spring. 1. Tape the isolator pad to the top of the coil spring. Position the spring in the lower suspension arm pocket. Be sure that the coil spring is seated in the pocket. 2. Install Spring Compressor DD-1278 up through the lower suspension arm, coil spring upper shock mounting hole. 3. Tighten the tool nut to compress the coil spring. 4. Install the lower ball joint into the knuckle and tighten the nut to 127 Nm (94 ft. lbs.). Install cotter pin. 5. Remove the spring compressor tool. 6. Install the stabilizer bar link to the lower suspension arm and tighten nut to 47 Nm (35 ft. lbs.). 7. Install the shock absorber. 8. Install the wheel and tire assembly. 9. Remove support and lower the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Bushings > Page 5656 Suspension Spring ( Coil / Leaf ): Service and Repair Leaf Spring REMOVAL 1. Raise the vehicle at the frame. 2. Support the axle to relieve the weight of the axle from the springs. 3. Remove the wheel and tire assemblies. 4. Remove shocks from the spring plates. 5. Remove the nuts, the U-bolts and spring plate from the axle. 6. Remove the nut and bolt from the front spring eye. 7. Remove the nut and bolt form the rear spring eye. 8. Remove the spring from the vehicle. 9. Remove the shackle from the frame bracket. INSTALLATION 1. Install shackle on the frame bracket and install the nut and bolt finger tight. 2. Position the spring under the rear axle pad. Make sure the spring center bolt is inserted in the pad locating hole. 3. Align front spring eye with the bolt hole in the front frame bracket. Install the spring eye bolt and nut and tighten the spring eye nut finger-tight. 4. Align spring shackle eye with the bolt hole in the rear frame bracket. Install the bolt and nut and tighten the spring shackle eye nut finger-tight. 5. Install the spring seat, U-bolts, spring plate, and nuts. 6. Tighten the U-bolt nuts to 122 Nm (90 ft. lbs.). 7. Install the shocks to the spring plates. 8. Install the wheel and tire assemblies. 9. Remove the support stands from under the frame rails. Lower the vehicle until the springs are supporting the weight of the vehicle. 10. Tighten the spring eye pivot bolt nut and all shackle nuts to 115 Nm (85 ft. lbs.). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Front Suspension Strut / Shock Absorber: Specifications Shock Absorber Upper Nut 19 ft.lb Lower Nut 21 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Front > Page 5661 Suspension Strut / Shock Absorber: Specifications Shock Absorber Lower Nut 70 ft.lb Upper Nut 70 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Front Suspension Strut / Shock Absorber: Description and Operation Front DESCRIPTION The top of the low-pressure gas charged shock are bolted to the frame. The bottom of the shock are bolted to the lower suspension arm. OPERATION The shock absorbers dampen jounce and rebound of the vehicle over various road conditions. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Front > Page 5664 Suspension Strut / Shock Absorber: Description and Operation Rear DESCRIPTION The top of the shock absorbers are bolted to the body crossmember. The bottom of the shocks are bolted to the axle brackets. OPERATION Ride control is accomplished through the use of dual-action shock absorbers. The shocks dampen the jounce and rebound as the vehicle travels over various road conditions. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front Suspension Strut / Shock Absorber: Testing and Inspection Front DIAGNOSIS AND TESTING - SHOCK ABSORBERS A knocking or rattling noise from a shock absorber may be caused by movement between mounting bushings and metal brackets or attaching components. These noises can usually be stopped by tightening the attaching nuts. If the noise persists, inspect for damaged and worn bushings, and attaching components. Repair as necessary if any of these conditions exist. A squeaking noise from the shock absorber may be caused by the hydraulic valving and may be intermittent. This condition is not repairable and the shock absorber must be replaced. The shock absorbers are not refillable or adjustable. If a malfunction occurs, the shock absorber must be replaced. 1b test a shock absorber, hold it in an upright position and force the piston in and out of the cylinder four or five times. The action throughout each stroke should be smooth and even. The shock absorber bushings do not require any type of lubrication. Do not attempt to stop bushing noise by lubricating them. Grease and mineral oil base lubricants will deteriorate the bushing. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front > Page 5667 Suspension Strut / Shock Absorber: Testing and Inspection Rear DIAGNOSIS AND TESTING - SPRING AND SHOCK A knocking or rattling noise from a shock absorber may be caused by movement between mounting bushings and metal brackets or attaching components. These noises can usually be stopped by tightening the attaching nuts. If the noise persists, inspect for damaged and worn bushings, and attaching components. Repair as necessary if any of these conditions exist. A squeaking noise from the shock absorber may be caused by the hydraulic valving and may be intermittent. This condition is not repairable and the shock absorber must be replaced. The shock absorbers are not refillable or adjustable. If a malfunction occurs, the shock absorber must be replaced. To test a shock absorber, hold it in an upright position and force the piston in and out of the cylinder four or five times. The action throughout each stroke should be smooth and even. The spring eye and shock absorber bushings do not require any type of lubrication. Do not attempt to stop spring bushing noise by lubricating them. Grease and mineral oil-base lubricants will deteriorate the bushing rubber. If the vehicle is used for severe, off-road operation, the springs should be examined periodically. Check for broken and shifted leafs, loose and missing clips, and broken center bolts. SPRING AND SHOCK ABSORBER Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Strut / Shock Absorber: Service and Repair Front REMOVAL 1. Remove the upper shock nut, retainer and grommet from the shock absorber stud. 2. Raise and support the vehicle. 3. Remove the lower mounting bolts and remove shock absorber through the lower suspension arm. INSTALLATION NOTE: Upper shock nut must be replaced or use Mopar Lock 'N Seal or Lactated 242 on existing nut. 1. Install the lower retainer (lower retainer is stamped with a L) and grommet on the shock absorber stud and extend the shock. Insert the shock absorber through the lower suspension arm and upper mounting hole. 2. Install the lower mounting bolts and tighten to 28 Nm (21 ft. lbs.). 3. Remove support and lower the vehicle. 4. Install the upper grommet and retainer (upper retainer is stamped with a U) on the shock absorber stud. Install a new nut or use Mopar Lock 'N Seal or Loctite 242 on existing nut and tighten to 26 Nm (19 ft. lbs.). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 5670 Suspension Strut / Shock Absorber: Service and Repair Rear REMOVAL 1. Raise vehicle and support rear axle. 2. Remove shock absorber lower nut and bolt from the spring plate. 3. Remove shock absorber upper nut and bolt from the frame bracket and remove the shock. INSTALLATION 1. Install shock absorber into upper frame bracket. Install bolt and nut and tighten nut to 95 Nm (70 ft. lbs.). 2. Install shock absorber into the spring plate. Install the bolt and nut and tighten nut to 95 Nm (70 ft. lbs.). 3. Remove axle support and lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Specifications Suspension Travel Bumper: Specifications Jounce Bumper Bolts 45 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Mechanical Specifications Wheel Bearing: Mechanical Specifications Hub/Bearing Spindle Nut 185 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Mechanical Specifications > Page 5678 Wheel Bearing: Fluid Type Specifications Use Mopar Multi-Purpose Lubricant or equivalent. (labeled NGLI Grade 2 EP, GC-LB) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 5679 Wheel Bearing: Service and Repair REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove brake caliper, rotor, and ABS wheel speed sensor if equipped. 4. Remove hub/bearing spindle nut and discard nut. CAUTION: The hub/bearing spindle nut can not be re-used. INSTALLATION 1. Slide hub/bearing on spindle. 2. Install new spindle nut and tighten to 251 Nm (185 ft. lbs.). 3. Install brake rotor, caliper, and ABS wheel speed sensor if equipped. 4. Install wheel and tire assembly. 5. Remove support and lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Specifications Wheel Hub: Specifications Hub/Bearing Spindle Nut 185 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Specifications > Page 5683 Wheel Hub: Service and Repair REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove brake caliper, rotor, and ABS wheel speed sensor if equipped. 4. Remove hub/bearing spindle nut and discard nut. CAUTION: The hub/bearing spindle nut can not be re-used. INSTALLATION 1. Slide hub/bearing on spindle. 2. Install new spindle nut and tighten to 251 Nm (185 ft. lbs.). 3. Install brake rotor, caliper, and ABS wheel speed sensor if equipped. 4. Install wheel and tire assembly. 5. Remove support and lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Description and Operation Spare Tire: Description and Operation DESCRIPTION - SPARE TIRE & TEMPORARY The temporary spare tire is designed for emergency use only. The original tire should be repaired or replaced at the first opportunity, then reinstalled. Do not exceed speeds of 50 M.P.H. when using the temporary spare tire. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Description and Operation > Page 5689 Spare Tire: Service and Repair SPARE TIRE WINCH REMOVAL 1. Remove spare tire. 2. Remove bolts attaching spare tire winch to crossmember. 3. Disengage clip attaching extension tube to spare tire winch. 4. Separate snare tire winch from vehicle. INSTALLATION 1. Position extension tube on spare tire winch and engage clip. 2. Position spare tire winch on vehicle. 3. Install bolts attaching spare tire winch to spare tire bracket. 4. Install spare tire. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Description and Operation Wheels: Description and Operation DESCRIPTION The rim size is on the vehicle safety certification label located on the drivers door shut face. The size of the rim is determined by the drivetrain package. Original equipment wheels/rims are designed for operation up to the specified maximum vehicle capacity. Fig. 1 All models use stamped steel, cast aluminum or forged aluminum wheels. Every wheel has raised sections between the rim flanges and rim drop well called safety humps. Initial inflation of the tire forces the bead over these raised sections. In case of rapid loss of air pressure, the raised sections help hold the tire on the wheel. The wheel studs and nuts are designed for specific applications. All aluminum and some steel wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Do not use replacement studs or nuts with a different design or lesser quality. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Description and Operation > Page 5693 Wheels: Testing and Inspection WHEEL REPLACEMENT Wheels must be replaced if they have: Excessive runout - Bent or dented - Leak air through welds - Have damaged bolt holes Wheel repairs employing hammering, heating, or welding are not allowed. Original equipment wheels are available through your dealer. Replacement wheels from any other source should be equivalent in: Load carrying capacity - Diameter - Width - Offset - Mounting configuration Failure to use equivalent replacement wheels may affect the safety and handling of your vehicle. Replacement with used wheels is not recommended. Their service history may have included severe treatment. WHEEL INSPECTION Inspect wheels for: Excessive run out - Dents or cracks - Damaged wheel lug nut holes - Air Leaks from any area or surface of the rim NOTE: Do not attempt to repair a wheel by hammering, heating or welding. If a wheel is damaged an original equipment replacement wheel should be used. When obtaining replacement wheels, they should be equivalent in load carrying capacity. The diameter, width, offset, pilot hole and bolt circle of the wheel should be the same as the original wheel. WARNING: FAILURE TO USE EQUIVALENT REPLACEMENT WHEELS MAY ADVERSELY AFFECT THE SAFETY AND HANDLING OF THE VEHICLE. USED WHEELS ARE NOT RECOMMENDED. THE SERVICE HISTORY OF THE WHEEL MAY HAVE INCLUDED SEVERE TREATMENT OR VERY HIGH MILEAGE. THE RIM COULD FAIL WITHOUT WARNING. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Mechanical Specifications Wheel Bearing: Mechanical Specifications Hub/Bearing Spindle Nut 185 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Mechanical Specifications > Page 5698 Wheel Bearing: Fluid Type Specifications Use Mopar Multi-Purpose Lubricant or equivalent. (labeled NGLI Grade 2 EP, GC-LB) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 5699 Wheel Bearing: Service and Repair REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove brake caliper, rotor, and ABS wheel speed sensor if equipped. 4. Remove hub/bearing spindle nut and discard nut. CAUTION: The hub/bearing spindle nut can not be re-used. INSTALLATION 1. Slide hub/bearing on spindle. 2. Install new spindle nut and tighten to 251 Nm (185 ft. lbs.). 3. Install brake rotor, caliper, and ABS wheel speed sensor if equipped. 4. Install wheel and tire assembly. 5. Remove support and lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Specifications Wheel Hub: Specifications Hub/Bearing Spindle Nut 185 ft.lb Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Specifications > Page 5703 Wheel Hub: Service and Repair REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove brake caliper, rotor, and ABS wheel speed sensor if equipped. 4. Remove hub/bearing spindle nut and discard nut. CAUTION: The hub/bearing spindle nut can not be re-used. INSTALLATION 1. Slide hub/bearing on spindle. 2. Install new spindle nut and tighten to 251 Nm (185 ft. lbs.). 3. Install brake rotor, caliper, and ABS wheel speed sensor if equipped. 4. Install wheel and tire assembly. 5. Remove support and lower vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Tightening Sequence Wheel Fastener: Specifications Tightening Sequence Wheel Torque Sequence - Master Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Tightening Sequence > Page 5708 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 5709 Wheel Fastener: Service and Repair STUDS REMOVAL - WHEEL STUDS 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper, caliper adapter and rotor. Fig. 9 4. Remove the stud from the hub with Remover C-4150A. INSTALLATION - WHEEL STUDS 1. Install the new stud into the hub flange. 2. Install the three washers onto stud, then install lug nut with the flat side of the nut against the washers. 3. Tighten the lug nut until the stud is pulled into the hub flange. Verify that the stud is properly seated into the flange. 4. Remove the lug nut and washers. 5. Install the brake rotor, caliper adapter, and caliper. 6. Install the wheel and tire assembly, use new lug nut on the stud or studs that were replaced. 7. Remove the support and lower the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Actuator / Motor: > 24-011-01 > Sep > 01 > Defroster Outlets - Whistling Sound Technical Service Bulletin # 24-011-01 Date: 010907 Defroster Outlets - Whistling Sound NUMBER: 24-011-01 GROUP: Heating and Air Conditioning DATE: Sept. 7, 2001 SUBJECT: Heater A/C System Whistle OVERVIEW: This bulletin involves installing air deflectors in the instrument panel center air outlets and installing a revised actuator cam and floor door lever. MODELS: 2001 (AN) Dakota 2001 (DN) Durango SYMPTOM/CONDITION: Some vehicles may exhibit a whistling sound coming from the defroster outlets, low air flow at the floor in the floor mode or side glass fogging at low ambient temperatures when the blower is operated at higher speeds. DIAGNOSIS: Operate the blower at M1, M2 and high speed with mode switch positioned in the Floor mode, at the detent between Floor/Panel and Floor and at the dentent between Floor/Defrost and Floor. If the whistling sound is present, perform the Repair Procedure. If customers complain of the foot well being too warm after extended driving or of the side glass fogging, perform the Repair Procedure. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Turn the ignition switch to the "on" position and place A/C control in floor mode. Turn the ignition switch off. 2. Disconnect battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Actuator / Motor: > 24-011-01 > Sep > 01 > Defroster Outlets - Whistling Sound > Page 5720 3. Remove center console. 4. Remove cluster bezel. 5. Remove knee blocker and lower center instrument panel trim panel. 6. Remove kick panels and lower door trim strip in order to free-up carpet. 7. Remove short instrument panel support brace (Fig. 1) located near the accelerator pedal. 8. Peel front carpet back for access. 9. Remove center instrument panel bolts (2), left and right instrument panel attaching bolts (4) and instrument panel roll-back bolts (2). 10. Grasp metal at center of the lower instrument panel and pry the instrument panel away from dash panel (2 in.). Place spacer in that gap to keep instrument panel in place. 11. Disassemble tunnel slider duct from floor duct (DN ONLY). 12. The floor duct that is attached to the HVAC unit is assembled in two pieces. Remove two screws that hold the passenger side of the floor duct to the HVAC unit. Remove the duct. 13. Remove two screws that hold the driver side of the floor duct to the HVAC unit. Remove the duct. 14. On the driver's side half of the floor duct, use an alcohol-based solvent to clean the seal surface before seal application. 15. Take the driver's side floor duct and install the foam seal provided and apply it to the seal surface. Be sure to press the seal to the duct firmly along the entire length of the seal. Set duct aside. 16. Remove foam seal on floor outlet of HVAC unit. Be careful to leave no adhesive residue on the housing. 17. Insert right larger deflector onto the passenger side forward (Closest to the engine compartment) flange of the heat outlet with the extension flap outboard as shown. Snap into place until positive lock is heard 18. Insert left air deflector onto the driver side forward flange of the heat outlet as shown. Snap into place until positive lock is heard 19. Make sure that both deflectors have tension on them and do not rattle. If they do, remove, bend appropriately and re-install. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Actuator / Motor: > 24-011-01 > Sep > 01 > Defroster Outlets - Whistling Sound > Page 5721 20. Insert smaller deflectors (Fig. 2)- one on the passenger side forward flange of the heater outlet and one on the driver side rearward (Closest to the passenger compartment) flange of the heater outlet. Snap into place until positive lock is heard. 21. Make sure that both deflectors have tension on them and do not rattle. If they do, remove, bend appropriately and re-install. 22. Carefully slide driver's side floor duct half (now with foam seal attached) into place. Be sure to carefully slide the duct into opening without rolling over the foam seal. After seal is properly sandwiched between the duct half and housing, Install the two attachment screws. 23. Slide passenger side floor duct half into place. Make sure this half properly mates with the driver's side half. Install the two attachment screws. 24. Remove the mode actuator from the driver's side of the HVAC unit. (If vehicle is a DN, remove both mode actuators on this side. 25. Remove cam and discard. 26. Close the floor door and note the position of the floor door lever. Remove floor door lever and discard. 27. Position floor door in closed position. While holding the floor door in the closed position, install new floor door lever supplied in the repair kit in the position noted earlier. Make sure the lever snaps and locks into place. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Actuator / Motor: > 24-011-01 > Sep > 01 > Defroster Outlets - Whistling Sound > Page 5722 28. Set the template over panel door and floor door levers as shown (Fig. 3). 29. Lay defrost lever on the outboard face of the cam. Install new cam aligning the hole in the cam with the mark on the template as shown (Fig. 3). Make sure that the proper pins fit into the proper traces on the cam back of the cam per the template. Remove template. 30. Install actuator. 31. Install the remainder of the of the parts removed earlier by reversing the removal procedure. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Actuator / Motor: > 24-011-01 > Sep > 01 > Defroster Outlets - Whistling Sound Technical Service Bulletin # 24-011-01 Date: 010907 Defroster Outlets - Whistling Sound NUMBER: 24-011-01 GROUP: Heating and Air Conditioning DATE: Sept. 7, 2001 SUBJECT: Heater A/C System Whistle OVERVIEW: This bulletin involves installing air deflectors in the instrument panel center air outlets and installing a revised actuator cam and floor door lever. MODELS: 2001 (AN) Dakota 2001 (DN) Durango SYMPTOM/CONDITION: Some vehicles may exhibit a whistling sound coming from the defroster outlets, low air flow at the floor in the floor mode or side glass fogging at low ambient temperatures when the blower is operated at higher speeds. DIAGNOSIS: Operate the blower at M1, M2 and high speed with mode switch positioned in the Floor mode, at the detent between Floor/Panel and Floor and at the dentent between Floor/Defrost and Floor. If the whistling sound is present, perform the Repair Procedure. If customers complain of the foot well being too warm after extended driving or of the side glass fogging, perform the Repair Procedure. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Turn the ignition switch to the "on" position and place A/C control in floor mode. Turn the ignition switch off. 2. Disconnect battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Actuator / Motor: > 24-011-01 > Sep > 01 > Defroster Outlets - Whistling Sound > Page 5728 3. Remove center console. 4. Remove cluster bezel. 5. Remove knee blocker and lower center instrument panel trim panel. 6. Remove kick panels and lower door trim strip in order to free-up carpet. 7. Remove short instrument panel support brace (Fig. 1) located near the accelerator pedal. 8. Peel front carpet back for access. 9. Remove center instrument panel bolts (2), left and right instrument panel attaching bolts (4) and instrument panel roll-back bolts (2). 10. Grasp metal at center of the lower instrument panel and pry the instrument panel away from dash panel (2 in.). Place spacer in that gap to keep instrument panel in place. 11. Disassemble tunnel slider duct from floor duct (DN ONLY). 12. The floor duct that is attached to the HVAC unit is assembled in two pieces. Remove two screws that hold the passenger side of the floor duct to the HVAC unit. Remove the duct. 13. Remove two screws that hold the driver side of the floor duct to the HVAC unit. Remove the duct. 14. On the driver's side half of the floor duct, use an alcohol-based solvent to clean the seal surface before seal application. 15. Take the driver's side floor duct and install the foam seal provided and apply it to the seal surface. Be sure to press the seal to the duct firmly along the entire length of the seal. Set duct aside. 16. Remove foam seal on floor outlet of HVAC unit. Be careful to leave no adhesive residue on the housing. 17. Insert right larger deflector onto the passenger side forward (Closest to the engine compartment) flange of the heat outlet with the extension flap outboard as shown. Snap into place until positive lock is heard 18. Insert left air deflector onto the driver side forward flange of the heat outlet as shown. Snap into place until positive lock is heard 19. Make sure that both deflectors have tension on them and do not rattle. If they do, remove, bend appropriately and re-install. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Actuator / Motor: > 24-011-01 > Sep > 01 > Defroster Outlets - Whistling Sound > Page 5729 20. Insert smaller deflectors (Fig. 2)- one on the passenger side forward flange of the heater outlet and one on the driver side rearward (Closest to the passenger compartment) flange of the heater outlet. Snap into place until positive lock is heard. 21. Make sure that both deflectors have tension on them and do not rattle. If they do, remove, bend appropriately and re-install. 22. Carefully slide driver's side floor duct half (now with foam seal attached) into place. Be sure to carefully slide the duct into opening without rolling over the foam seal. After seal is properly sandwiched between the duct half and housing, Install the two attachment screws. 23. Slide passenger side floor duct half into place. Make sure this half properly mates with the driver's side half. Install the two attachment screws. 24. Remove the mode actuator from the driver's side of the HVAC unit. (If vehicle is a DN, remove both mode actuators on this side. 25. Remove cam and discard. 26. Close the floor door and note the position of the floor door lever. Remove floor door lever and discard. 27. Position floor door in closed position. While holding the floor door in the closed position, install new floor door lever supplied in the repair kit in the position noted earlier. Make sure the lever snaps and locks into place. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Actuator / Motor: > 24-011-01 > Sep > 01 > Defroster Outlets - Whistling Sound > Page 5730 28. Set the template over panel door and floor door levers as shown (Fig. 3). 29. Lay defrost lever on the outboard face of the cam. Install new cam aligning the hole in the cam with the mark on the template as shown (Fig. 3). Make sure that the proper pins fit into the proper traces on the cam back of the cam per the template. Remove template. 30. Install actuator. 31. Install the remainder of the of the parts removed earlier by reversing the removal procedure. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Page 5731 Air Door Actuator / Motor: Locations The single zone blend door actuator is located on the driver side end of the heater-A/C housing unit, close to the dash panel. In the dual zone system, a second separate blend door actuator is also located on the driver side end of the heater-A/C housing unit close to the instrument panel. The single recirculation door actuator is located on the passenger side end of the heater-A/C housing unit, on the bottom of the lower intake air housing. The single mode door actuator is located on the driver side end of the heater-A/C housing unit, close to the top of the distribution housing. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Blend Door Actuator Air Door Actuator / Motor: Diagrams Blend Door Actuator Driver Blend Door Actuator Passenger Blend Door Actuator Rear Blend Door Actuator Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Blend Door Actuator > Page 5734 Recirculation Door Actuator Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Blend Door Actuator > Page 5735 Air Door Actuator / Motor: Diagrams Mode Door Actuator Mode Door Actuator Rear Mode Door Actuator Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Page 5736 Air Door Actuator / Motor: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator Air Door Actuator / Motor: Description and Operation Blend Door Actuator BLEND DOOR ACTUATOR - FRONT The blend door actuators are reversible, 12-volt Direct Current (DC), servo motors. Models with the single zone heater and air conditioner system have a single blend air door, which is controlled by a single blend door actuator. Models with the optional dual zone front heater and air conditioner system have dual blend air doors, which are controlled by two blend door actuators. The single zone blend door actuator is located on the driver side end of the heater-A/C housing unit, close to the dash panel. In the dual zone system, the same blend door actuator used for the single zone system becomes the passenger blend door actuator, and is mechanically connected to only the passenger side blend air door. In the dual zone system, a second separate blend door actuator is also located on the driver side end of the heater-A/C housing unit close to the instrument panel, and is mechanically connected to only the driver side blend air door. The blend door actuators are interchangeable with each other, as well as with the actuators for the mode door and the recirculation air door. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle. Two integral mounting tabs allow the actuator to be secured with two screws to the heater-A/C unit housing. Each actuator also has an identical output shaft with splines that connects it to the link-age that drives the proper blend air door. The blend door actuators do not require mechanical indexing to the blend door linkage, as they are electronically calibrated by the heater-A/C control module. The blend door actuators cannot be adjusted or repaired and, if damaged or faulty, they must be replaced. Each blend door actuator is connected to the heater-A/C control module through the vehicle electrical system by a dedicated two-wire take out and connector of the HAVC wire harness. The blend door actuator can move the blend air door in two directions. When the heater-A/C control module pulls the voltage on one side of the motor connection high and the other connection low, the blend air door will move in one direction. When the module reverses the polarity of the voltage to the motor, the blend air door moves in the opposite direction. When the module makes the voltage to both connections high or both connections low, the blend air door stops and will not move. These same motor connections also provide a feedback signal to the heater-A/C control module. This feedback signal allows the module to monitor the operation and relative positions of the blend door actuator and the blend air door. The heater-A/C control module learns the blend air door stop positions during the calibration procedure and will store a Diagnostic Trouble Code (DTC) for any problems it detects in the blend door actuator circuits. The blend door actuator can be diagnosed using a DRB III scan tool. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator > Page 5739 Air Door Actuator / Motor: Description and Operation Fresh Air/Recirculation Actuator RECIRCULATION DOOR ACTUATOR - FRONT The recirculation door actuator is a reversible, 12-volt Direct Current (DC), servo motor. The single recirculation door actuator is located on the passenger side end of the heater-A/C housing unit, on the bottom of the lower intake air housing. The recirculation door actuator is mechanically connected to the recirculation air door. The recirculation door actuator is interchangeable with the actuators for the blend air door(s) and the mode door. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle. Two integral mounting tabs allow the actuator to be secured with two screws to the lower intake air housing. Each actuator also has an identical output shaft with splines that connects it to the linkage that drives the recirculation air door. The recirculation door actuator does not require mechanical indexing to the recirculation air door; as it is electronically calibrated by the heater-A/C control module. The recirculation door actuator cannot be adjusted or repaired and, if damaged or faulty, it must be replaced. The recirculation door actuator is connected to the heater-A/C control module through the vehicle electrical system by a dedicated two-wire take out and connector of the HVAC wire harness. The recirculation door actuator can move the recirculation door in two directions. When the heater-A/C control module pulls the voltage on one side of the motor connection high and the other connection low, the recirculation air door will move in one direction. When the module reverses the polarity of the voltage to the motor; the recirculation air door moves in the opposite direction. When the module makes the voltage to both connections high or both connections low, the recirculation air door stops and will not move. These same motor connections also provide a feedback signal to the heater-A/C control module. This feedback signal allows the module to monitor the operation and relative position of the recirculation door actuator and the recirculation air door. The heater-A/C control module learns the recirculation air door stop positions during the calibration procedure and will store a Diagnostic Trouble Code (DTC) for any problems it detects in the recirculation door actuator circuits. The recirculation door actuator can be diagnosed using a DRB III scan tool. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator > Page 5740 Air Door Actuator / Motor: Description and Operation Mode Door Actuator MODE DOOR ACTUATOR - FRONT The mode door actuator is a reversible, 12-volt Direct Current (DC), servo motor. The single mode door actuator is located on the driver side end of the heater-A/C housing unit, close to the top of the distribution housing. The mode door actuator is mechanically connected to the mode door. The mode door actuator is interchangeable with the actuators for the blend air door(s) and the recirculation air door. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle. Two integral mounting tabs allow the actuator to be secured with two screws to the heater-A/C unit housing. Each actuator also has an identical output shaft with splines that connects it to the linkage that drives the mode door. The mode door actuator does not require mechanical indexing to the mode door linkage, as it is electronically calibrated by the heater-A/C control module. The mode door actuator cannot be adjusted or repaired and, if damaged or faulty, it must be replaced. The mode door actuator is connected to the heaterA/C control module through the vehicle electrical system by a dedicated two-wire take out and connector of the HVAC wire harness. The mode door actuator can move the mode door in two directions. When the heater-A/C control module pulls the voltage on one side of the motor connection high and the other connection low, the mode door will move in one direction. When the module reverses the polarity of the voltage to the motor, the mode door moves in the opposite direction. When the module makes the voltage to both connections high or both connections low, the mode door stops and will not move. These same motor connections also provide a feedback signal to the heater-A/C control module. This feedback signal allows the module to monitor the operation and relative position of the mode door actuator and the mode door. The heater-A/C control module learns the mode door stop positions during the calibration procedure and will store a Diagnostic Trouble Code (DTC) for any problems it detects in the mode door actuator circuits. The mode door actuator can be diagnosed using a DRB III scan tool. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator Replacement Air Door Actuator / Motor: Service and Repair Blend Door Actuator Replacement REMOVAL The single zone heating and air conditioning system is equipped with a single blend door actuator. The dual zone system has two blend door actuators, one for the driver side blend air door and one for the passenger side blend air door. The same service procedures can be used for each of these actuators. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the silencer from beneath the driver side end of the instrument panel. 3. Remove the three screws that secure the heater core shield to the left end of the HVAC distribution housing. 4. Pull the heater core shield rearward far enough to disengage the two location tabs that position the front of the shield to the receptacles in the two lower finger formations of the heater/air conditioner housing near the dash panel. 5. Remove the heater core shield from the distribution housing. 6. Disconnect the HVAC wire harness connector for the blend door actuator from the actuator connector receptacle. 7. Remove the two screws that secure the blend door actuator to the distribution housing. 8. Remove the blend door actuator from the distribution housing. INSTALLATION 1. Position the blend door actuator onto the heater/air conditioner housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the blend air door linkage. 2. Install and tighten the two screws that secure the blend door actuator to the distribution housing. Tighten the screws to 2 Nm (17 in. lbs.). 3. Reconnect the HVAC wire harness connector for the blend door actuator to the actuator connector receptacle. 4. Position the heater core shield onto the distribution housing. Be certain that the two location tabs on the front of the shield are engaged in the receptacles in the two lower finger formations of the evaporator housing near the dash panel. 5. Install and tighten the three screws that secure the heater core shield to the left end of the heater/air conditioner housing. Tighten the screws to 2 Nm (17 in. lbs.). 6. Reinstall the silencer under the driver side end of the instrument panel. 7. Reconnect the battery negative cable. 8. The DRM lll is used to perform the heater-A/C control calibration procedure. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator Replacement > Page 5743 Air Door Actuator / Motor: Service and Repair Fresh Air/Recirculation Actuator Replacement REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Pull the carpet on the passenger side front floor away from the dash panel far enough to access the recirculation door actuator. 3. Disconnect the HVAC wire harness connector for the recirculation door actuator from the actuator connector receptacle. 4. Remove the two screws that secure the recirculation door actuator to the lower intake air housing. 5. Remove the recirculation door actuator from the lower intake air housing. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the recirculation door actuator onto the lower intake air housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the recirculation air door. 2. Install and tighten the two screws that secure the recirculation door actuator to the lower intake air housing. Tighten the screws to 2 Nm (17 in. lbs.). 3. Reconnect the HVAC wire harness connector for the recirculation door actuator to the actuator connector receptacle. 4. Reposition the carpet on the passenger side front floor back up to the dash panel. 5. Reconnect the battery negative cable. 6. The DRM lll is used to perform the heater-A/C control calibration procedure. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator Replacement > Page 5744 Air Door Actuator / Motor: Service and Repair Mode Door Actuator Replacement REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the silencer from beneath the driver side end of the instrument panel. 3. Disconnect the HVAC wire harness connector for the mode door actuator from the actuator connector receptacle. 4. Remove the two screws that secure the mode door actuator to the distribution housing. 5. Remove the mode door actuator from the distribution housing. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the mode door actuator onto the heater/AC housing. If necessary; rotate the actuator slightly to align the splines on the actuator output shaft with those in the mode door linkage. 2. Install and tighten the two screws that secure the mode door actuator to the distribution housing. Tighten the screws to 2 Nm (17 in. lbs.). 3. Reconnect the HVAC wire harness connector for the mode door actuator to the actuator connector receptacle. 4. Reinstall the silencer under the driver side end of the instrument panel. 5. Reconnect the battery negative cable. 6. The DRM lll is used to perform the heater-A/C control calibration procedure.. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service Precautions Air Duct: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Outlets Replacement Air Duct: Service and Repair Air Outlets Replacement REMOVAL 1. The rear overhead A/C outlets are used on models with the optional rear heater-A/C unit. 2. Using a trim stick or another suitable wide flat-blade tool, gently pry between both ends of the rear heater-A/C outlet bezel and the headliner to release the two snap clip retainers that secure the bezel to the headliner. 3. Remove the outlets from the rear headliner mounting hole. INSTALLATION 1. Install the outlets into the rear headliner mounting hole. 2. Gently push the outlet housing into the mounting hole until secure and the two outlet snap clips engage. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Outlets Replacement > Page 5750 Air Duct: Service and Repair Defroster Ducts Replacement REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel from the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly 3. Place the instrument panel face down on a suitable work surface. Be certain to take the proper precautions to protect the face of the instrument panel from cosmetic damage. 4. Remove the fasteners that secure the defroster duct to the instrument panel armature. 5. Remove the defroster duct from the instrument panel. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the defroster duct to the instrument panel. 2. Install the fasteners that secure the defroster duct to the instrument panel armature. 3. Reinstall the instrument panel in the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly 4. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Outlets Replacement > Page 5751 Air Duct: Service and Repair Ducts and Outlets Replacement REMOVAL Rear Floor Heat Duct Split Bench Seat Fig. 2 Rear Seat Floor Duct Control - Split Bench Seat 1. Remove the three retainers that secure the HVAC rear bezel to the brackets near the back of the front seat center. 2. Pull the bezel away from the back of the front seat far enough to access and disengage the control cable retainer and cable end from the control. Bucket Seat The rear floor duct control and linkage are only serviced as a unit with the console duct assembly. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Outlets Replacement > Page 5752 Fig. 3 Rear Seat Floor Duct Control - Bucket Seat 1. Remove the four screws that secure the console bin and remove the bin from the floor console. 2. Reach through the top of the console to disengage the control rod end from the floor duct damper door pivot. 3. Remove the floor console from the vehicle and disassemble as required to remove the console duct and control assembly from the console as a unit. Refer to Body for the procedures. Rear Seat Floor Duct The rear seat floor duct damper door is only serviceable as part of the rear seat floor duct on bench seat models, or the center seat floor duct on bucket seat models. 1. Remove the carpeting from the floor panel transmission tunnel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Outlets Replacement > Page 5753 Fig. 1 Rear HVAC Housing Fig. 4 Rear Seat Floor Ducts Remove/Install - Bucket Seat Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Outlets Replacement > Page 5754 Fig. 5 Rear Seat Floor Ducts Remove/Install - Split Bench Seat 2. Remove the retainers that secure the ducts to the floor panel transmission tunnel 3. Remove the duct(s) from the floor panel as required. INSTALLATION Split Bench Seat 1. Install the bezel to the back of the front seat far enough to allow access to engage the control cable retainer and cable end to the controller. 2. Install the three retainers that secure the HVAC rear bezel to the brackets near the back of the front seat center. Bucket Seat 1. Assemble the floor console as required to install duct and control assembly. 2. Install floor console into vehicle. 3. Reach through the top of the console to engage the control rod end to the floor duct damper door pivot. 4. Install the three retainers that secure the HVAC rear bezel to the brackets near the back of the front seat center. Rear Seat Floor Duct 1. Install the duct(s) to the floor panel as required. 2. Install the retainers that secure the ducts to the floor panel transmission tunnel. 3. Install the carpeting to the floor panel transmission tunnel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Outlets Replacement > Page 5755 Air Duct: Service and Repair Floor Distribution Ducts Replacement REMOVAL 1. Roll back the carpet on the front floor from under the instrument panel toward the rear of the vehicle. 2. Lift the center floor distribution duct upward far enough to disengage its locator hole from the weld stud on the front floor panel. 3. Pull the floor distribution duct assembly rearward far enough to disengage the center floor distribution duct from the outlet on the bottom of the heater-A/C housing unit. INSTALLATION 1. Assemble the right and/or left floor distribution ducts onto the center floor distribution duct as required. 2. Slide the floor distribution duct assembly under the instrument panel center stack far enough to engage the center floor distribution duct with the outlet on the bottom of the heater-A/C housing unit. 3. Align the locator hole on the center floor distribution duct with the weld stud on the front floor panel. 4. Using hand pressure, push the locator hole of the center floor distribution duct down over the weld stud on the front floor panel. 5. Reinstall the carpet onto the front floor panel and under the instrument panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Outlets Replacement > Page 5756 Air Duct: Service and Repair Air Outlets Replacement REMOVAL 1. The rear overhead A/C outlets are used on models with the optional rear heater-A/C unit. 2. Using a trim stick or another suitable wide flat-blade tool, gently pry between both ends of the rear heater-A/C outlet bezel and the headliner to release the two snap clip retainers that secure the bezel to the headliner. 3. Remove the outlets from the rear headliner mounting hole. INSTALLATION 1. Install the outlets into the rear headliner mounting hole. 2. Gently push the outlet housing into the mounting hole until secure and the two outlet snap clips engage. Defroster Ducts Replacement REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel from the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly 3. Place the instrument panel face down on a suitable work surface. Be certain to take the proper precautions to protect the face of the instrument panel from cosmetic damage. 4. Remove the fasteners that secure the defroster duct to the instrument panel armature. 5. Remove the defroster duct from the instrument panel. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the defroster duct to the instrument panel. 2. Install the fasteners that secure the defroster duct to the instrument panel armature. 3. Reinstall the instrument panel in the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly 4. Reconnect the battery negative cable. Ducts and Outlets Replacement REMOVAL Rear Floor Heat Duct Split Bench Seat Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Outlets Replacement > Page 5757 Fig. 2 Rear Seat Floor Duct Control - Split Bench Seat 1. Remove the three retainers that secure the HVAC rear bezel to the brackets near the back of the front seat center. 2. Pull the bezel away from the back of the front seat far enough to access and disengage the control cable retainer and cable end from the control. Bucket Seat The rear floor duct control and linkage are only serviced as a unit with the console duct assembly. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Outlets Replacement > Page 5758 Fig. 3 Rear Seat Floor Duct Control - Bucket Seat 1. Remove the four screws that secure the console bin and remove the bin from the floor console. 2. Reach through the top of the console to disengage the control rod end from the floor duct damper door pivot. 3. Remove the floor console from the vehicle and disassemble as required to remove the console duct and control assembly from the console as a unit. Refer to Body for the procedures. Rear Seat Floor Duct The rear seat floor duct damper door is only serviceable as part of the rear seat floor duct on bench seat models, or the center seat floor duct on bucket seat models. 1. Remove the carpeting from the floor panel transmission tunnel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Outlets Replacement > Page 5759 Fig. 1 Rear HVAC Housing Fig. 4 Rear Seat Floor Ducts Remove/Install - Bucket Seat Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Outlets Replacement > Page 5760 Fig. 5 Rear Seat Floor Ducts Remove/Install - Split Bench Seat 2. Remove the retainers that secure the ducts to the floor panel transmission tunnel 3. Remove the duct(s) from the floor panel as required. INSTALLATION Split Bench Seat 1. Install the bezel to the back of the front seat far enough to allow access to engage the control cable retainer and cable end to the controller. 2. Install the three retainers that secure the HVAC rear bezel to the brackets near the back of the front seat center. Bucket Seat 1. Assemble the floor console as required to install duct and control assembly. 2. Install floor console into vehicle. 3. Reach through the top of the console to engage the control rod end to the floor duct damper door pivot. 4. Install the three retainers that secure the HVAC rear bezel to the brackets near the back of the front seat center. Rear Seat Floor Duct 1. Install the duct(s) to the floor panel as required. 2. Install the retainers that secure the ducts to the floor panel transmission tunnel. 3. Install the carpeting to the floor panel transmission tunnel. Floor Distribution Ducts Replacement REMOVAL 1. Roll back the carpet on the front floor from under the instrument panel toward the rear of the vehicle. 2. Lift the center floor distribution duct upward far enough to disengage its locator hole from the weld stud on the front floor panel. 3. Pull the floor distribution duct assembly rearward far enough to disengage the center floor distribution duct from the outlet on the bottom of the heater-A/C housing unit. INSTALLATION 1. Assemble the right and/or left floor distribution ducts onto the center floor distribution duct as required. 2. Slide the floor distribution duct assembly under the instrument panel center stack far enough to engage the center floor distribution duct with the outlet on the bottom of the heater-A/C housing unit. 3. Align the locator hole on the center floor distribution duct with the weld stud on the front floor panel. 4. Using hand pressure, push the locator hole of the center floor distribution duct down over the weld stud on the front floor panel. 5. Reinstall the carpet onto the front floor panel and under the instrument panel. Instrument Panel Demister Ducts Replacement REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Outlets Replacement > Page 5761 CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel from the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly 3. Place the instrument panel face down on a suitable work surface. Be certain to take the proper precautions to protect the face of the instrument panel from cosmetic damage. 4. Remove the fasteners that secure the demister ducts to the instrument panel armature. 5. Disengage the demister ducts from the demister outlets. 6. Remove the demister ducts from the instrument panel. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the demister ducts to the instrument panel. 2. Engage the demister ducts to the demister outlets. 3. Install the fasteners that secure the demister ducts to the instrument panel armature. 4. Reinstall the instrument panel into the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly 5. Reconnect the battery negative cable. Instrument Panel Ducts Replacement REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel from the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly 3. Place the instrument panel face down on a suitable work surface. Be certain to take the proper precautions to protect the face of the instrument panel from cosmetic damage. 4. Remove the fasteners that secure the panel ducts to the instrument panel armature. 5. Disengage the panel ducts from the panel outlets. 6. Remove the panel ducts from the instrument panel. INSTALLATION 1. Position the panel ducts to the instrument panel. 2. Engage the panel ducts to the panel outlets. 3. Install the fasteners that secure the panel ducts to the instrument panel armature. 4. Reinstall the instrument panel into the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly 5. Reconnect the battery negative cable. Rear Floor Heat Duct Replacement Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Outlets Replacement > Page 5762 REMOVAL Fig. 2 Rear Seat Floor Duct Control - Split Bench Seat Split Bench Seat 1. Remove the three retainers that secure the HVAC rear bezel to the brackets near the back of the front seat center. 2. Pull the bezel away from the back of the front seat far enough to access and disengage the control cable retainer and cable end from the control. Bucket Seat The rear floor duct control and linkage are only serviced as a unit with the console duct assembly. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Outlets Replacement > Page 5763 Fig. 3 Rear Seat Floor Duct Control - Bucket Seat 1. Remove the four screws that secure the console bin and remove the bin from the floor console. 2. Reach through the top of the console to disengage the control rod end from the floor duct damper door pivot. 3. Remove the floor console from the vehicle and disassemble as required to remove the console duct and control assembly from the console as a unit. Rear Seat Floor Duct The rear seat floor duct damper door is only serviceable as part of the rear seat floor duct on bench seat models, or the center seat floor duct on bucket seat models. 1. Remove the carpeting from the floor panel transmission tunnel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Outlets Replacement > Page 5764 Fig. 1 Rear HVAC Housing Fig. 4 Rear Seat Floor Ducts Remove/Install - Bucket Seat Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Outlets Replacement > Page 5765 Fig. 5 Rear Seat Floor Ducts Remove/Install - Split Bench Seat 2. Remove the retainers that secure the ducts to the floor panel transmission tunnel 3. Remove the duct(s) from the floor panel as required. INSTALLATION Split Bench Seat 1. Install the bezel to the back of the front seat far enough to allow access to engage the control cable retainer and cable end to the controller. 2. Install the three retainers that secure the HVAC rear bezel to the brackets near the back of the front seat center. Bucket Seat 1. Assemble the floor console as required to install duct and control assembly. 2. Install floor console into vehicle. 3. Reach through the top of the console to engage the control rod end to the floor duct damper door pivot. 4. Install the three retainers that secure the HVAC rear bezel to the brackets near the back of the front seat center. Rear Seat Floor Duct 1. Install the duct(s) to the floor panel as required. 2. Install the retainers that secure the ducts to the floor panel transmission tunnel. 3. Install the carpeting to the floor panel transmission tunnel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > Customer Interest for Air Register: > 24-011-01 > Sep > 01 > Defroster Outlets - Whistling Sound Technical Service Bulletin # 24-011-01 Date: 010907 Defroster Outlets - Whistling Sound NUMBER: 24-011-01 GROUP: Heating and Air Conditioning DATE: Sept. 7, 2001 SUBJECT: Heater A/C System Whistle OVERVIEW: This bulletin involves installing air deflectors in the instrument panel center air outlets and installing a revised actuator cam and floor door lever. MODELS: 2001 (AN) Dakota 2001 (DN) Durango SYMPTOM/CONDITION: Some vehicles may exhibit a whistling sound coming from the defroster outlets, low air flow at the floor in the floor mode or side glass fogging at low ambient temperatures when the blower is operated at higher speeds. DIAGNOSIS: Operate the blower at M1, M2 and high speed with mode switch positioned in the Floor mode, at the detent between Floor/Panel and Floor and at the dentent between Floor/Defrost and Floor. If the whistling sound is present, perform the Repair Procedure. If customers complain of the foot well being too warm after extended driving or of the side glass fogging, perform the Repair Procedure. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Turn the ignition switch to the "on" position and place A/C control in floor mode. Turn the ignition switch off. 2. Disconnect battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > Customer Interest for Air Register: > 24-011-01 > Sep > 01 > Defroster Outlets - Whistling Sound > Page 5774 3. Remove center console. 4. Remove cluster bezel. 5. Remove knee blocker and lower center instrument panel trim panel. 6. Remove kick panels and lower door trim strip in order to free-up carpet. 7. Remove short instrument panel support brace (Fig. 1) located near the accelerator pedal. 8. Peel front carpet back for access. 9. Remove center instrument panel bolts (2), left and right instrument panel attaching bolts (4) and instrument panel roll-back bolts (2). 10. Grasp metal at center of the lower instrument panel and pry the instrument panel away from dash panel (2 in.). Place spacer in that gap to keep instrument panel in place. 11. Disassemble tunnel slider duct from floor duct (DN ONLY). 12. The floor duct that is attached to the HVAC unit is assembled in two pieces. Remove two screws that hold the passenger side of the floor duct to the HVAC unit. Remove the duct. 13. Remove two screws that hold the driver side of the floor duct to the HVAC unit. Remove the duct. 14. On the driver's side half of the floor duct, use an alcohol-based solvent to clean the seal surface before seal application. 15. Take the driver's side floor duct and install the foam seal provided and apply it to the seal surface. Be sure to press the seal to the duct firmly along the entire length of the seal. Set duct aside. 16. Remove foam seal on floor outlet of HVAC unit. Be careful to leave no adhesive residue on the housing. 17. Insert right larger deflector onto the passenger side forward (Closest to the engine compartment) flange of the heat outlet with the extension flap outboard as shown. Snap into place until positive lock is heard 18. Insert left air deflector onto the driver side forward flange of the heat outlet as shown. Snap into place until positive lock is heard 19. Make sure that both deflectors have tension on them and do not rattle. If they do, remove, bend appropriately and re-install. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > Customer Interest for Air Register: > 24-011-01 > Sep > 01 > Defroster Outlets - Whistling Sound > Page 5775 20. Insert smaller deflectors (Fig. 2)- one on the passenger side forward flange of the heater outlet and one on the driver side rearward (Closest to the passenger compartment) flange of the heater outlet. Snap into place until positive lock is heard. 21. Make sure that both deflectors have tension on them and do not rattle. If they do, remove, bend appropriately and re-install. 22. Carefully slide driver's side floor duct half (now with foam seal attached) into place. Be sure to carefully slide the duct into opening without rolling over the foam seal. After seal is properly sandwiched between the duct half and housing, Install the two attachment screws. 23. Slide passenger side floor duct half into place. Make sure this half properly mates with the driver's side half. Install the two attachment screws. 24. Remove the mode actuator from the driver's side of the HVAC unit. (If vehicle is a DN, remove both mode actuators on this side. 25. Remove cam and discard. 26. Close the floor door and note the position of the floor door lever. Remove floor door lever and discard. 27. Position floor door in closed position. While holding the floor door in the closed position, install new floor door lever supplied in the repair kit in the position noted earlier. Make sure the lever snaps and locks into place. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > Customer Interest for Air Register: > 24-011-01 > Sep > 01 > Defroster Outlets - Whistling Sound > Page 5776 28. Set the template over panel door and floor door levers as shown (Fig. 3). 29. Lay defrost lever on the outboard face of the cam. Install new cam aligning the hole in the cam with the mark on the template as shown (Fig. 3). Make sure that the proper pins fit into the proper traces on the cam back of the cam per the template. Remove template. 30. Install actuator. 31. Install the remainder of the of the parts removed earlier by reversing the removal procedure. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Register: > 24-011-01 > Sep > 01 > Defroster Outlets - Whistling Sound Technical Service Bulletin # 24-011-01 Date: 010907 Defroster Outlets - Whistling Sound NUMBER: 24-011-01 GROUP: Heating and Air Conditioning DATE: Sept. 7, 2001 SUBJECT: Heater A/C System Whistle OVERVIEW: This bulletin involves installing air deflectors in the instrument panel center air outlets and installing a revised actuator cam and floor door lever. MODELS: 2001 (AN) Dakota 2001 (DN) Durango SYMPTOM/CONDITION: Some vehicles may exhibit a whistling sound coming from the defroster outlets, low air flow at the floor in the floor mode or side glass fogging at low ambient temperatures when the blower is operated at higher speeds. DIAGNOSIS: Operate the blower at M1, M2 and high speed with mode switch positioned in the Floor mode, at the detent between Floor/Panel and Floor and at the dentent between Floor/Defrost and Floor. If the whistling sound is present, perform the Repair Procedure. If customers complain of the foot well being too warm after extended driving or of the side glass fogging, perform the Repair Procedure. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Turn the ignition switch to the "on" position and place A/C control in floor mode. Turn the ignition switch off. 2. Disconnect battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Register: > 24-011-01 > Sep > 01 > Defroster Outlets - Whistling Sound > Page 5782 3. Remove center console. 4. Remove cluster bezel. 5. Remove knee blocker and lower center instrument panel trim panel. 6. Remove kick panels and lower door trim strip in order to free-up carpet. 7. Remove short instrument panel support brace (Fig. 1) located near the accelerator pedal. 8. Peel front carpet back for access. 9. Remove center instrument panel bolts (2), left and right instrument panel attaching bolts (4) and instrument panel roll-back bolts (2). 10. Grasp metal at center of the lower instrument panel and pry the instrument panel away from dash panel (2 in.). Place spacer in that gap to keep instrument panel in place. 11. Disassemble tunnel slider duct from floor duct (DN ONLY). 12. The floor duct that is attached to the HVAC unit is assembled in two pieces. Remove two screws that hold the passenger side of the floor duct to the HVAC unit. Remove the duct. 13. Remove two screws that hold the driver side of the floor duct to the HVAC unit. Remove the duct. 14. On the driver's side half of the floor duct, use an alcohol-based solvent to clean the seal surface before seal application. 15. Take the driver's side floor duct and install the foam seal provided and apply it to the seal surface. Be sure to press the seal to the duct firmly along the entire length of the seal. Set duct aside. 16. Remove foam seal on floor outlet of HVAC unit. Be careful to leave no adhesive residue on the housing. 17. Insert right larger deflector onto the passenger side forward (Closest to the engine compartment) flange of the heat outlet with the extension flap outboard as shown. Snap into place until positive lock is heard 18. Insert left air deflector onto the driver side forward flange of the heat outlet as shown. Snap into place until positive lock is heard 19. Make sure that both deflectors have tension on them and do not rattle. If they do, remove, bend appropriately and re-install. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Register: > 24-011-01 > Sep > 01 > Defroster Outlets - Whistling Sound > Page 5783 20. Insert smaller deflectors (Fig. 2)- one on the passenger side forward flange of the heater outlet and one on the driver side rearward (Closest to the passenger compartment) flange of the heater outlet. Snap into place until positive lock is heard. 21. Make sure that both deflectors have tension on them and do not rattle. If they do, remove, bend appropriately and re-install. 22. Carefully slide driver's side floor duct half (now with foam seal attached) into place. Be sure to carefully slide the duct into opening without rolling over the foam seal. After seal is properly sandwiched between the duct half and housing, Install the two attachment screws. 23. Slide passenger side floor duct half into place. Make sure this half properly mates with the driver's side half. Install the two attachment screws. 24. Remove the mode actuator from the driver's side of the HVAC unit. (If vehicle is a DN, remove both mode actuators on this side. 25. Remove cam and discard. 26. Close the floor door and note the position of the floor door lever. Remove floor door lever and discard. 27. Position floor door in closed position. While holding the floor door in the closed position, install new floor door lever supplied in the repair kit in the position noted earlier. Make sure the lever snaps and locks into place. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Register: > 24-011-01 > Sep > 01 > Defroster Outlets - Whistling Sound > Page 5784 28. Set the template over panel door and floor door levers as shown (Fig. 3). 29. Lay defrost lever on the outboard face of the cam. Install new cam aligning the hole in the cam with the mark on the template as shown (Fig. 3). Make sure that the proper pins fit into the proper traces on the cam back of the cam per the template. Remove template. 30. Install actuator. 31. Install the remainder of the of the parts removed earlier by reversing the removal procedure. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams Ambient Temperature Sensor / Switch HVAC: Diagrams Ambient Temperature Sensor Ambient Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Page 5788 Ambient Temperature Sensor / Switch HVAC: Description and Operation AMBIENT TEMP SENSOR - FRONT Ambient air temperature is monitored by the compass mini-trip computer module through the ambient temperature sensor. The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the right side of the radiator yoke, behind the radiator grille and in front of the engine compartment. For complete circuit diagrams, refer to Overhead Console in the Contents of Wiring Diagrams. The ambient temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent to it by the compass mini-trip computer module. The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the compass mini-trip computer module. Based upon the resistance in the sensor, the compass mini-trip computer module senses a specific voltage on the temperature sensor signal circuit, which it is programmed to correspond to a specific temperature. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Page 5789 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection The thermometer function is supported by the ambient temperature sensor, a wiring circuit, and a portion of the compass mini-trip computer module. If any portion of the ambient temperature sensor circuit fails, the compass/thermometer display function will self-diagnose the circuit. An "SC" (short circuit) will appear in the display in place of the temperature, when the sensor is exposed to temperatures above 110 °C (230 °F), or if the sensor circuit is shorted. An "OC", (open circuit) will appear in the display in place of the temperature, when the sensor is exposed to temperatures below -50 °C (-58 ° F), or if the sensor circuit is open. The ambient temperature sensor circuit can also be diagnosed using the following Sensor Test, and Sensor Circuit Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, refer to Compass Mini-Trip Computer in the Diagnosis and Testing. For complete circuit diagrams, refer to Overhead Console in the Contents of Wiring Diagrams. Sensor Test 1. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor wire harness connector. 2. Measure the resistance of the ambient temperature sensor. At -40 °C (-40 °F), the sensor resistance is 336 kilo ohms. At -55 °C (131 °F), the sensor resistance is 2.488 kilo ohms. The sensor resistance should read between these two values. If OK, refer to Sensor Circuit Test in the Diagnosis and Testing. If not OK, replace the faulty ambient temperature sensor. Sensor Circuit Test 1. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor wire harness connector and the overhead console wire harness connector. 2. Connect a jumper wire between the two terminals in the body half of the ambient temperature sensor wire harness connector. 3. Check for continuity between the sensor return circuit and the ambient temperature sensor signal circuit cavities of the roof wire harness overhead console connector. There should be continuity. If OK, go to Step 4. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 4. Remove the jumper wire from the body half of the ambient temperature sensor wire harness connector. Check for continuity between the sensor return circuit cavity of the roof wire harness overhead console connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted sensor return circuit as required. 5. Check for continuity between the ambient temperature sensor signal circuit cavity of the roof wire harness overhead console connector and a good ground. There should be no continuity. If OK, refer to Compass Mini-Trip Computer in the Diagnosis and Testing. If not OK, repair the shorted ambient temperature sensor signal circuit as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Page 5790 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Fig. 17 Ambient Temperature Sensor Remove/Install 2. Locate the ambient temperature sensor, on the right side of the radiator yoke behind the grille. 3. Disconnect the wire harness connector from the ambient temperature sensor connector receptacle. 4. Remove the one screw that secures the ambient temperature sensor bracket to the radiator yoke. 5. Remove the ambient temperature sensor from the radiator yoke. INSTALLATION 1. Position the ambient temperature sensor onto the radiator yoke. 2. Install and tighten the one screw that secures the ambient temperature sensor bracket to the radiator yoke. Tighten the screw to 5.6 Nm (50 in. lbs.) . 3. Reconnect the wire harness connector to the ambient temperature sensor connector receptacle. 4. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations Blower Motor: Locations The front blower motor and blower wheel are located in the passenger side end of the heater-A/C housing, below the glove box. The rear blower motor and blower wheel are located inside the rear heater-A/C unit, which is located in the right rear quarter panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions Blower Motor: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5796 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5797 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5798 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5799 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5800 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5801 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5802 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5803 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5804 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5805 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5806 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5807 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5808 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5809 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5810 Blower Motor: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5811 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5812 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5813 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5814 Blower Motor: Connector Views Blower Motor Rear Blower Motor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5815 Heating & A/C - Front Blower Motor Schematic Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 5816 Blower Motor: Service Precautions WARNING: - ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - REVIEW THE WARNINGS AND CAUTIONS IN THE GENERAL INFORMATION BEFORE PERFORMING THE FOLLOWING OPERATION. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 5817 Blower Motor: Description and Operation BLOWER MOTOR - FRONT The blower motor and blower wheel are located in the passenger side end of the heater-A/C housing, below the glove box. The blower motor controls the velocity of air flowing through the heater-A/C housing by spinning a squirrel cage-type blower wheel within the housing at the selected speed. The blower motor and blower wheel can only be serviced with the heater-A/C housing removed from the passenger compartment. The blower motor will only operate when the ignition switch is in the ON position, and the heater-A/C mode control switch knob is in any position, except OFF. The blower motor receives a fused battery feed through the blower motor relay (Voltage Reduction Relay or VRR) whenever the ignition switch is in the ON position. The blower motor battery feed circuit is protected by a fuse in the Power Distribution Center (PDC). The blower motor relay control circuit is protected by a fuse in the junction block. Blower motor speed is controlled by regulating the ground path through the heater-A/C mode control switch, the blower motor switch, the blower motor resistor, the blower motor relay (VRR), and the high speed blower motor relay. The blower motor and blower motor wheel cannot be repaired and, if faulty or damaged, they must be replaced. The blower motor and blower wheel are each serviced separately. BLOWER MOTOR - REAR The rear blower motor and blower wheel are located inside the rear heater-A/C unit, which is located in the right rear quarter panel. The blower motor controls the velocity of air flowing through the rear heater-A/C unit by spinning a wide squirrel cage-type blower wheel within the housing at the selected speed. Rear blower motor speed is controlled by regulating the ground path through the rear blower motor switch and the rear blower motor resistor. The rear blower motor will only operate when the ignition switch is in the On position and the front heater-A/C control is set to either front control of rear heater-A/C unit or the rear control position of the rear heater-A/C unit. The rear blower motor receives a fused battery feed through a fuse in the relay and fuse block whenever the ignition switch is in the ON position. The relay and fuse block is attached to the back of the junction block, under the left side of the instrument panel in the passenger compartment. The rear blower motor, blower wheel, and blower wheel housing cannot be repaired and, if faulty or damaged, they must be replaced as a complete factory-balanced unit. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 5818 Blower Motor: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Possible causes of an inoperative front or rear blower motor include: - Faulty fuse (the rear blower motor fuse is located in the relay and fuse block located on the back of the junction block) - Faulty blower motor circuit wiring or wire harness connectors - Faulty blower motor resistor - Faulty blower motor relay (Voltage Reduction Relay or VRR) (front only) - Faulty blower motor switch - Faulty heater-A/C mode control switch (front only) - Faulty high speed blower motor relay (front only) - Faulty blower motor. Possible causes of the front or rear blower motor not operating in all speeds include: - Faulty fuse (the rear blower motor fuse is located in the relay and fuse block located on the back of the junction block) - Faulty blower motor switch - Faulty blower motor resistor - Faulty blower motor relay (front only) - Faulty blower motor circuit wiring or wire harness connectors - Faulty high speed blower motor relay (front only). Vibration Possible causes of front or rear blower motor vibration include: Improper blower motor mounting - Improper blower wheel mounting - Blower wheel out of balance or deformed - Blower motor faulty. Noise To determine that the rear blower is the source of the noise, simply switch the blower motor from OFF to ON. There are no other moving parts involved in the rear heater-A/C unit, which makes it simple to identify the source of the noise. To verify that the front blower is the source of the noise, unplug the front blower motor wire harness connector and operate the heater-A/C system. If the noise goes away, possible causes include: Foreign material in the heater-A/C housing - Improper blower motor mounting - Improper blower wheel mounting - Blower motor faulty. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Front Blower Motor Blower Motor: Service and Repair Front Blower Motor REMOVAL 1. Remove the lower right kick panel. 2. Carefully pull carpeting back from trim panel and front cowl to gain additional clearance for blower motor assembly. 3. Remove the three screws that secure the blower motor, air spoiler, and blower wheel assembly to the heater-A/C housing 4. Pull the blower motor and wheel assembly out of the passenger compartment side of the heater-A/C housing while feeding the blower motor wire harness, grommet and connector through the hole on the dash panel side of the housing. INSTALLATION 1. Place the blower motor, air spoiler, and wheel assembly inside the heater-A/C housing and feed the blower motor wire harness connector through the grommet hole in the dash panel side of the housing. 2. Pull the blower motor wiring through the hole from the dash panel side of the heater-A/C housing until the grommet is seated, while positioning the blower motor and blower wheel assembly inside the housing. 3. Install the three screws that secure the blower motor, air spoiler, and wheel assembly to the heater- A/C housing. Tighten the screws to 2.2 Nm (20 in. lbs.). 4. Plug blower motor connections together. 5. Carefully install passenger side carpet. 6. Install lower right kick panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Front Blower Motor > Page 5821 Blower Motor: Service and Repair Rear Blower Motor REMOVAL The rear blower motor is used only on models with the optional rear heater-A/C unit. Because the rear blower motor and wheel are factory balanced units, the rear blower motor, wheel, housing and mounting hardware are serviced only as a complete unit. 1. Disconnect and isolate the battery negative cable. 2. Remove the right rear inside trim panel from the passenger compartment of the vehicle. Refer to Body for the procedures. 3. Unplug the motor connector. 4. Remove the three blower motor retaining screws. 5. Remove the blower motor from the rear heater- A/C housing. INSTALLATION The rear blower motor is used only on models with the optional rear heater-A/C unit. Because the rear blower motor and wheel are factory balanced units, the rear blower motor and wheel are serviced only as a complete unit. 1. Position the rear blower motor and wheel to the rear heater-A/C unit, and start the three mounting screws to hold it in position. 2. Engage the rear A/C unit wire harness in the routing holes on each end of the blower housing. 3. Finish installing the three rear blower motor and wheel mounting screws. Tighten the mounting screws to 3 Nm (27 in. lbs.). 4. Plug in the rear blower motor wire harness connector. 5. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations Power Distribution Center Blower Motor Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 5825 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 5826 Blower Motor Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 5827 Rear Blower Motor Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations Blower Motor Resistor: Locations The blower motor resistor for the optional rear A/C unit is located within the unit housing. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 5831 Blower Motor Resistor: Diagrams Blower Motor Resistor Block Rear Blower Motor Resistor Block Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 5832 Blower Motor Resistor: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 5833 Blower Motor Resistor: Description and Operation BLOWER MOTOR RESISTOR BLOCK - FRONT During vehicle assembly, the blower motor resistor is mounted to the HVAC unit inside the passenger compartment. It can be accessed from the passenger foot well area. See Blower Motor Resistor in the Removal and Installation for more information. Fig. 1 Rear Blower Motor Wheel/Resistor The blower motor resistor for the optional rear A/C unit is located within the unit housing. The resistor has multiple resistor wires, each of which will change the resistance in the blower motor ground path to change the blower motor speed. The blower motor switch located in the A/C control head directs the ground path through the correct resistor wire to obtain the selected blower motor speed. The resistor has multiple resistor circuits each of which will change the resistance in the blower motor ground path to change the blower motor speed. The blower motor switch directs the ground path through the correct resistor circuit to obtain the selected blower motor speed. With the blower motor switch in the lowest speed position, the ground path for the motor is applied through all of the resistor circuits. Each higher speed selected with the blower motor switch applies the blower motor ground path through fewer of the resistor circuits, increasing the blower motor speed. The blower motor resistor cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 5834 Fig. 1 Rear Blower Motor Wheel/Resistor BLOWER MOTOR RESISTOR BLOCK - REAR The blower motor resistor for the optional rear A/C unit is located within the unit housing. The resistor has multiple resistor wires, each of which will change the resistance in the blower motor ground path to change the blower motor speed. The blower motor switch located in the A/C control head directs the ground path through the correct resistor wire to obtain the selected blower motor speed. With the blower motor switch in the lowest speed position, the ground path for the motor is applied through all of the resistor wires. Each higher speed selected with the blower motor switch applies the blower motor ground path through fewer of the resistor wires, increasing the blower motor speed. When the blower motor switch is in the highest speed position, the blower motor resistor is bypassed and the blower motor receives a direct path to ground. The blower motor resistor cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Testing and Inspection > Front Blower Motor Resistor Blower Motor Resistor: Testing and Inspection Front Blower Motor Resistor Both the front blower motor resistor and the optional rear heater-A/C unit blower motor resistor can be diagnosed using the procedure that follows. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the blower motor resistor. 3. Check for continuity between each of the blower motor switch input terminals of the resistor and the resistor output terminal. In each case there should be continuity. If OK, repair the wire harness circuits between the blower motor switch and the blower motor resistor or blower motor as required. If not OK, replace the faulty blower motor resistor. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Testing and Inspection > Front Blower Motor Resistor > Page 5837 Blower Motor Resistor: Testing and Inspection Rear Blower Motor Resistor Both the front blower motor resistor and the optional rear heater-A/C unit blower motor resistor can be diagnosed using the procedure that follows. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the blower motor resistor. 3. Check for continuity between each of the blower motor switch input terminals of the resistor and the resistor output terminal. In each case there should be continuity. If OK, repair the wire harness circuits between the blower motor switch and the blower motor resistor or blower motor as required. If not OK, replace the faulty blower motor resistor. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Front Blower Motor Resistor: Service and Repair Front REMOVAL 1. Disconnect and isolate the battery negative cable. 2. From the passenger foot well area, remove the two hex screws used to secure the blower motor resistor. 3. Unplug the front blower motor resistor from the wire harness connector. 4. Pull the front blower motor resistor and its wire harness out of the plenum panel and through the cowl plenum access hole far enough to access the wire harness connector. 5. Remove the front blower motor resistor from the cowl plenum. INSTALLATION 1. Plug the front blower motor resistor into the wire harness connector. 2. Install the front blower motor resistor to the HVAC unit. (orientation required). 3. Install and tighten the two screws that secure the HVAC unit. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). 4. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Front > Page 5840 Blower Motor Resistor: Service and Repair Rear REMOVAL The rear blower motor resistor is used only on models with the optional rear A/C unit. 1. Disconnect and isolate the battery negative cable. 2. Remove the right rear quarter panel interior trim from the passenger compartment of the vehicle. 3. Unplug the rear blower motor resistor wire harness connector. 4. Remove the screw that secures the rear blower motor resistor bracket to the rear A/C unit housing. 5. Remove the rear blower motor resistor and bracket as a unit from the rear A/C unit. INSTALLATION 1. Position the rear blower motor resistor and bracket in the right rear corner of the rear A/C unit and secure it with the mounting screw. Tighten the mounting screw to 2.2 N.m (20 in. lbs.). 2. Plug in the rear blower motor resistor wire harness connector. 3. Engage the rear blower motor resistor wire harness connector retainer to the mounting hole in the right rear corner of the rear A/C unit. 4. Reinstall the right rear quarter panel interior trim to the passenger compartment of the vehicle. 5. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Description and Operation Blower Motor Switch: Description and Operation BLOWER MOTOR SWITCH - FRONT The heater-A/C blower motor is controlled by a four position rotary-type blower motor switch, mounted in the heater-A/C control panel. The switch allows the selection of one of four blower motor speeds, but can only be turned OFF by selecting the OFF position with the heater-A/C mode control switch knob. The blower motor switch directs the blower motor ground path through the mode control switch to the blower motor resistor, or directly to ground through the high speed blower motor relay, as required to achieve the selected blower motor speed. The blower motor switch cannot be repaired and, if faulty or damaged, the entire heater-A/C control unit must be replaced. The blower motor switch knob is serviced separately. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Description and Operation > Page 5844 Blower Motor Switch: Testing and Inspection For circuit descriptions, diagrams and electrical test procedures for blower switch. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Description and Operation > Page 5845 Blower Motor Switch: Service and Repair REMOVAL The rear blower motor switch is integrated into the rear control and is used only on models with the optional rear heater-A/C unit. 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick or another suitable wide flat-bladed tool, gently pry above the two indentations at the outer perimeter of the rear control to release it from the headliner. 3. Pull the rear blower motor switch away from the headliner far enough to access and unplug the wire harness connector from the back of the switch. 4. Remove the rear blower motor switch from the headliner. INSTALLATION The rear blower motor switch is used only on models with the optional rear heating-A/C unit. 1. Plug the wire harness connector into the back of the rear blower motor switch. 2. Tuck the wire harness back through the rear blower motor switch mounting hole in the headliner. 3. Gently press the rear blower motor switch into the mounting hole in the headliner until it snaps into place. 4. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Application and ID Cabin Air Filter: Application and ID This vehicle is not equipped with a cabin air filter. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications Clutch Air Gap ..................................................................................................................................... ............................. 0.41 - 0.79 mm (0.016 - 0.031 in.) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5853 A/C Compressor Clutch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5854 Compressor Clutch: Description and Operation Fig. 1 Compressor Clutch - Typical A/C COMPRESSOR CLUTCH - FORNT The compressor clutch assembly consists of a stationary electromagnetic coil, a hub bearing and pulley assembly, and a clutch plate. The electromagnetic coil unit and the hub bearing and pulley assembly are each retained on the nose of the compressor front housing with snap rings. The clutch plate is mounted to the compressor shaft and secured with a nut. These components provide the means to engage and disengage the compressor from the engine serpentine accessory drive belt. When the clutch coil is energized, it magnetically draws the clutch into contact with the pulley and drives the compressor shaft. When the coil is not energized, the pulley freewheels on the clutch hub bearing, which is part of the pulley. The compressor clutch and coil are the only serviced parts on the compressor. The compressor clutch engagement is controlled by several components: the heater-A/C mode control switch, the evaporator temperature sensor, the loss of charge cut-off switch, the pressure transducer, the compressor clutch relay, and the Powertrain Control Module (PCM). The PCM may delay compressor clutch engagement for up to thirty seconds. Refer to Fuel System for more information on the PCM controls. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5855 Compressor Clutch: Testing and Inspection Examine the friction surfaces of the clutch pulley and the front plate for wear. The pulley and front plate should be replaced if there is excessive wear or scoring. If the friction surfaces are oily, inspect the shaft and nose area of the compressor for oil. Remove the felt from the front cover. If the felt is saturated with oil, the shaft seal is leaking and the compressor must be replaced. Check the clutch pulley bearing for roughness or excessive leakage of grease. Replace the bearing, if required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > A/C Compressor Clutch Break-In Compressor Clutch: Service and Repair A/C Compressor Clutch Break-In After a new compressor clutch has been installed, cycle the compressor clutch approximately twenty times (five seconds ON, then five seconds OFF). During this procedure, set the a/c heater control to the recirculation mode (Max-A/C), the blower motor switch to the highest speed position, and the engine speed at 1500 to 2000 rpm. This procedure (burnishing) will seat the opposing friction surfaces and provide a higher compressor clutch torque capability. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > A/C Compressor Clutch Break-In > Page 5858 Compressor Clutch: Service and Repair A/C Compressor Clutch Replacement REMOVAL The refrigerant system can remain fully-charged during compressor clutch, pulley, or coil replacement. The compressor clutch can be serviced in the vehicle. 1. Disconnect and isolate the battery negative cable. 2. Remove the serpentine drive belt. Refer to Cooling for the procedures. 3. Unplug the compressor clutch coil wire harness connector. Fig. 2 Clutch Nut Remove 4. Insert the two pins of the spanner wrench (Special Tool 6462 in Kit 6460) into the holes of the clutch plate. Hold the clutch plate stationary and remove the hex nut. 5. Remove the clutch plate and the clutch shims. Fig. 3 External Snap Ring Remove 6. Remove the external front housing snap ring with snap ring pliers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > A/C Compressor Clutch Break-In > Page 5859 Fig. 4 Shaft Protector And Puller 7. Install the lip of the rotor puller (Special Tool C-6141-1 in Kit 6460) into the snap ring groove exposed in Step 6, and install the shaft protector (Special Tool C-6141-2 in Kit 6460). Fig. 5 Install Puller Plate 8. Install the puller through-bolts (Special Tool C-6461) through the puller flange and into the jaws of the rotor puller and tighten. Turn the puller center bolt clockwise until the rotor pulley is free. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > A/C Compressor Clutch Break-In > Page 5860 Fig. 6 Clutch Coil Lead Wire Harness 9. Remove the screw and retainer from the clutch coil lead wire harness on the compressor front housing. Fig. 7 Clutch Field Coil Snap Ring Remove 10. Remove the snap ring from the compressor hub and remove the clutch field coil. Slide the clutch field coil off of the compressor hub. INSTALLATION 1. Install the clutch field coil and snap ring. 2. Install the clutch coil lead wire harness retaining clip on the compressor front housing and tighten the retaining screw. 3. Align the rotor assembly squarely on the front compressor housing hub. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > A/C Compressor Clutch Break-In > Page 5861 Fig. 8 Rotor Installer Set 4. Thread the handle (Special Tool 6464 in Kit 6460) into the driver (Special Tool 6143 in Kit 6460). Fig. 9 Rotor Install 5. Place the driver tool assembly into the bearing cavity on the rotor. Make certain the outer edge of the tool rests firmly on the rotor bearing inner race. 6. Tap the end of the driver while guiding the rotor to prevent binding. Tap until the rotor bottoms against the compressor front housing hub. Listen for a distinct change of sound during the tapping process, to indicate the bottoming of the rotor. 7. Install the external front rotor snap ring with snap ring pliers. The bevel side of the snap ring must be facing outward. Press the snap ring to make sure it is properly seated in the groove. CAUTION: If the snap ring is not fully seated in the groove it will vibrate out, resulting in a clutch failure and severe damage to the front housing of the compressor. 8. Install the original clutch shims on the compressor shaft. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > A/C Compressor Clutch Break-In > Page 5862 Fig. 10 Clutch Plate Install 9. Install the clutch plate. Use the shaft protector (Special Tool 6141-2 in Kit 6460) to install the clutch plate on the compressor shaft. Tap the clutch plate over the compressor shaft until it has bottomed against the clutch shims. Listen for a distinct change of sound during the tapping process, to indicate the bottoming of the clutch plate. 10. Replace the compressor shaft hex nut. Tighten the nut to 14.4 Nm (10.5 ft. lbs.). Fig. 11 Check Clutch Air Gap 11. Check the clutch air gap with a feeler gauge. If the air gap does not meet the specification, add or subtract shims as required. The air gap specification is 0.41 to 0.79 millimeter (0.016 to 0.031 inch). If the air gap is not consistent around the circumference of the clutch, lightly pry up at the minimum variations. Lightly tap down at the points of maximum variation. NOTE: The air gap is determined by the spacer shims. When installing an original, or a new clutch assembly, try the original shims first. When installing a new clutch onto a compressor that previously did not have a clutch, use 1.0, 0.50, and 0.13 millimeter (0.040, 0.020, and 0.005 inch) shims from the clutch hardware package that is provided with the new clutch. 12. To complete the procedure. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Testing and Inspection Compressor Clutch Coil: Testing and Inspection The battery must be fully-charged before performing the following tests. Refer to Battery for more information. 1. Connect an ammeter (0 to 10 ampere scale) in series with the clutch coil terminal. Use a voltmeter (0 to 20 volt scale) with clip-type leads for measuring the voltage across the battery and the compressor clutch coil. 2. With the heater-A/C mode control switch in any A/C mode, and the blower motor switch in the lowest speed position, start the engine and run it at normal idle. 3. The compressor clutch coil voltage should read within two volts of the battery voltage. If there is voltage at the clutch coil, but the reading is not within two volts of the battery voltage, test the clutch coil feed circuit for excessive voltage drop and repair as required. If there is no voltage reading at the clutch coil, use a DRB scan tool and the proper Diagnostic Procedures for testing of the compressor clutch circuit. The following components must be checked and repaired as required before you can complete testing of the clutch coil: Fuses in the junction block and the Power Distribution Center (PDC) - Heater-A/C mode control switch - Compressor clutch relay - Evaporator temperature sensor - Pressure transducer - Loss of charge - Powertrain Control Module (PCM). 4. The compressor clutch coil is acceptable if the current draw measured at the clutch coil is 2.0 to 3.9 amperes with the electrical system voltage at 11.5 to 12.5 volts. This should only be checked with the work area temperature at 21 °C (70 °F). If system voltage is more than 12.5 volts, add electrical loads by turning on electrical accessories until the system voltage drops below 12.5 volts. a. If the clutch coil current reading is four amperes or more, the coil is shorted and should be replaced. b. If the clutch coil current reading is zero, the coil is open and should be replaced. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Power Distribution Center A/C Clutch Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5869 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5870 Compressor Clutch Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5871 A/C Compressor Clutch Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5872 Compressor Clutch Relay: Description and Operation COMPRESSOR CLUTCH RELAY - FRONT The compressor clutch relay is an International Standards Organization (ISO) micro-relay. The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (footprint) is different, the current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The compressor clutch relay is an electromechanical device that switches battery current to the compressor clutch coil when the Powertrain Control Module (PCM) grounds the coil side of the relay. The PCM responds to inputs from the heater-A/C mode control switch, the evaporator temperature sensor, the loss of charge switch, and the pressure transducer. See Compressor Clutch Relay in the Diagnosis and Testing for more information. The compressor clutch relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identification and location. The compressor clutch relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5873 Compressor Clutch Relay: Testing and Inspection Fig.12 Compressor Clutch Relay RELAY TEST The compressor clutch relay is located in the Power Distribution Center (PDC). Refer to the PDC label for relay identification and location. Remove the relay from the PDC to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see the Relay Circuit Test below. If not OK, replace the faulty relay. RELAY CIRCUIT TEST 1. The relay common feed terminal cavity (30) is connected to fused battery feed. There should be battery voltage at the cavity for relay terminal 30 at all times. If OK, go to Step 2. If not OK, repair the open circuit to the fuse in the PDC as required. 2. The relay normally closed terminal (87A) is not used in this application. Go to Step 3. 3. The relay normally open terminal cavity (87) is connected to the compressor clutch coil. There should be continuity between this cavity and the A/C compressor clutch relay output circuit cavity of the compressor clutch coil wire harness connector. If OK, go to Step 4. If not OK, repair the open circuit as required. 4. The relay coil battery terminal (86) is connected to the fused ignition switch output (run/start) circuit. There should be battery voltage at the cavity for relay terminal 86 with the ignition switch in the ON position. If OK, go to Step 5. If not OK, repair the open circuit to the fuse in the junction block as required. 5. The coil ground terminal cavity (85) is switched to ground through the Powertrain Control Module (PCM). There should be continuity between this cavity and the A/C compressor clutch relay control circuit cavity of the PCM wire harness connector C (gray) at all times. If not OK, repair the open circuit as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5874 Compressor Clutch Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Fig. 13 Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for compressor clutch relay identification and location. 4. Unplug the compressor clutch relay from the PDC. INSTALLATION 1. Install the compressor clutch relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 2. Install the PDC cover. 3. Connect the battery negative cable. 4. Test the relay operation. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications Condenser HVAC: Specifications Condenser Mounting Bolts ............................................................................................................................................... 10.7 N.m (8 Ft. Lbs) (95 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 5878 Condenser HVAC: Locations The condenser is located in the air flow in front of the engine cooling radiator. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 5879 Condenser HVAC: Description and Operation A/C CONDENSOR - FRONT The condenser is a heat exchanger that allows the high-pressure refrigerant gas being discharged by the compressor to give up its heat to the air passing over the condenser fins, thus causing the refrigerant to change to a liquid state. When the refrigerant gas gives up its heat, it condenses. When the refrigerant leaves the condenser, it has become a high-pressure liquid refrigerant. The volume of air flowing over the condenser fins is critical to the proper cooling performance of the air conditioning system. Therefore, it is important that there are no objects placed in front of the radiator grille openings in the front of the vehicle or foreign material on the condenser fins that might obstruct proper air flow. Also, any factory-installed air seals or shrouds must be properly reinstalled following radiator or condenser service. The condenser cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 5880 Condenser HVAC: Service and Repair REMOVAL CAUTION: Before removing the condenser, note the location of each of the radiator and condenser air seals. These seals are used to direct air through the condenser and radiator. The air seals must be reinstalled in their proper locations in order for the air conditioning and engine cooling systems to perform as designed. 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Fig. 2 Condenser Line Fittings 3. Disconnect the refrigerant line fitting that secures the discharge line to the condenser inlet. Install plugs in, or tape over all of the opened refrigerant line fittings. 4. Disconnect the refrigerant line fitting that secures the liquid line to the condenser outlet. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the two screws that secure the radiator and fan shroud module to the inside of the upper radiator crossmember. 6. Remove the condenser cooling module from the vehicle. INSTALLATION CAUTION: Before removing the condenser, note the location of each of the radiator and condenser air seals These seals are used to direct air through the condenser and radiator. The air seals must be reinstalled in their proper locations in order for the air conditioning and engine cooling systems to perform as designed. 1. Remove the plugs or tape from the refrigerant line fittings on the liquid line and the condenser outlet. Connect the liquid line to the condenser outlet. Tighten the fitting to 22.59 ± 3.39 Nm (200 ± 30 in. lbs.). 2. Remove the plugs or tape from the refrigerant line fittings on the discharge line and the condenser inlet. Connect the discharge line to the condenser inlet. Tighten the fitting to 22.59 ± 3.39 Nm (200 ± 30 in. lbs.). 3. Check that all of the condenser and radiator air seals are in their proper locations. 4. Connect the battery negative cable. 5. Evacuate the refrigerant system. 6. Charge the refrigerant system. NOTE: If the condenser is replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Assembly: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle Technical Service Bulletin # 08-032-00A Date: 001229 4X4 Service Lamp - ON, 4X2 Vehicle NUMBER: 08-032-00 REV. A GROUP: Electrical DATE: Dec. 29, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-032-00, DATED OCTOBER 20, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS BULLETIN IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS SUBJECT: "Service 4WD" Lamp Illuminated On 4X2 Vehicles OVERVIEW: This bulletin involves installing a revised HVAC control assembly. MODELS: NOTE: THIS BULLETIN APPLIES TO 4X2 VEHICLES BUILT BEFORE OCTOBER 13, 2000 (MDH 1013XX). SYMPTOM/CONDITION: The "Service 4WD" lamp is illuminated even though the truck is not a 4X4 vehicle. DIAGNOSIS: Start the engine. Once the instrument cluster bulb check has been completed, verify that the "Service 4WD" lamp is illuminated. If the "Service 4WD" lamp is illuminated, perform the Repair Procedure. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Assembly: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 5889 FAILURE CODE: Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING INSTRUMENT PANEL COMPONENT SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is equipped with an automatic transmission, turn the ignition switch to the Unlock position, set the park brake, and place the transmission gear selector lever in the LOW position. 3. If the vehicle is equipped with a tilt column, set the tilt steering column in its lowest position. 4. Reach under the left end of the instrument panel to access and unsnap the rod end clip on the park brake release link and disengage the link from the back of the handle (Fig. 1). 5. Remove the three screws that secure the lower edge of the steering column opening cover to the lower instrument panel reinforcement. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Assembly: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 5890 6. Using a trim stick or another suitable wide flat-bladed tool, gently pry the upper edge of the steering column opening cover just below the cluster bezel on each side of the steering column away from the instrument panel far enough to disengage each of the snap clip retainers from their receptacles in the instrument panel base trim (Fig. 2). 7. Remove the steering column opening cover from the instrument panel. 8. Remove the two screws in the hooded area above the instrument cluster that secures the cluster bezel to the instrument panel base trim (Fig. 3). 9. Using a trim stick or another suitable wide flat-bladed tool, gently pry around the perimeter of the cluster bezel to disengage the snap clips from their receptacles in the instrument panel base trim. 10. Pull the right side of the cluster bezel away from the instrument panel far enough to access and disconnect the instrument panel wire harness connector for the headlamp switch from the switch connector receptacle. 11. Pull the left side of the cluster bezel away from the instrument panel far enough to access and disconnect the instrument panel wire harness connectors from the receptacles for the passenger airbag ON/OFF switch (if equipped), the rear window defogger switch (if equipped), the HVAC control, and the transfer case switch (if equipped). 12. Remove the cluster bezel from the instrument panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Assembly: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 5891 13. Remove the four screws that secure the HVAC control to the cluster bezel (Fig. 4). 14. Remove the HVAC control from the instrument panel. 15. Position the new HVAC control (see Parts Required section) in the cluster bezel and secure it with four screws. Tighten the screws to 2.2 Nm (17 i3 in. lbs.) 16. Position the cluster bezel to the instrument panel. 17. Pull the left side of the cluster bezel away from the instrument panel far enough to access and reconnect the instrument panel wire harness connectors to the receptacles for the passenger airbag on/off switch (if equipped), the rear window defogger switch (if equipped), the HVAC control, and the transfer case switch (if equipped). 18. Pull the right side of the cluster bezel away from the instrument panel far enough to access and reconnect the instrument panel wire harness connector for the headlamp switch to the switch connector receptacle. 19. Align the snap clips on the cluster bezel with the receptacles in the instrument panel base trim. 20. Using hand pressure, press firmly on the cluster bezel over each of the snap clip locations until each snap clip is fully engaged in their receptacle. 21. Install and tighten the two screws in the hooded area above the instrument cluster that secure the cluster bezel to the instrument panel base trim (Fig. 3). Tighten the screws to 2.2 Nm (20 in. lbs.). 22. Position the steering column opening cover to the instrument panel. 23. Align the snap clip retainers on the steering column opening cover with the receptacles in the instrument panel base trim. 24. Using hand pressure, press firmly on the steering column opening cover over the snap clip locations until each of the snap clips are fully engaged in their receptacle. 25. Install and tighten the three screws that secure the lower edge of the steering column opening cover to the instrument structural support. Tighten the screws to 2.2 Nm (20 in.lbs.). 26. Reach under the left end of the instrument panel to access and engage the park brake release link to the back of the handle. Then snap the rod end clip over the park brake release link to secure the connection. 27. Reconnect the battery negative cable. 28. On vehicles equipped with A/C, perform the A/C cool down test using the DRBIII(R). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle Technical Service Bulletin # 08-032-00A Date: 001229 4X4 Service Lamp - ON, 4X2 Vehicle NUMBER: 08-032-00 REV. A GROUP: Electrical DATE: Dec. 29, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-032-00, DATED OCTOBER 20, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS BULLETIN IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS SUBJECT: "Service 4WD" Lamp Illuminated On 4X2 Vehicles OVERVIEW: This bulletin involves installing a revised HVAC control assembly. MODELS: NOTE: THIS BULLETIN APPLIES TO 4X2 VEHICLES BUILT BEFORE OCTOBER 13, 2000 (MDH 1013XX). SYMPTOM/CONDITION: The "Service 4WD" lamp is illuminated even though the truck is not a 4X4 vehicle. DIAGNOSIS: Start the engine. Once the instrument cluster bulb check has been completed, verify that the "Service 4WD" lamp is illuminated. If the "Service 4WD" lamp is illuminated, perform the Repair Procedure. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 5897 FAILURE CODE: Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING INSTRUMENT PANEL COMPONENT SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is equipped with an automatic transmission, turn the ignition switch to the Unlock position, set the park brake, and place the transmission gear selector lever in the LOW position. 3. If the vehicle is equipped with a tilt column, set the tilt steering column in its lowest position. 4. Reach under the left end of the instrument panel to access and unsnap the rod end clip on the park brake release link and disengage the link from the back of the handle (Fig. 1). 5. Remove the three screws that secure the lower edge of the steering column opening cover to the lower instrument panel reinforcement. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 5898 6. Using a trim stick or another suitable wide flat-bladed tool, gently pry the upper edge of the steering column opening cover just below the cluster bezel on each side of the steering column away from the instrument panel far enough to disengage each of the snap clip retainers from their receptacles in the instrument panel base trim (Fig. 2). 7. Remove the steering column opening cover from the instrument panel. 8. Remove the two screws in the hooded area above the instrument cluster that secures the cluster bezel to the instrument panel base trim (Fig. 3). 9. Using a trim stick or another suitable wide flat-bladed tool, gently pry around the perimeter of the cluster bezel to disengage the snap clips from their receptacles in the instrument panel base trim. 10. Pull the right side of the cluster bezel away from the instrument panel far enough to access and disconnect the instrument panel wire harness connector for the headlamp switch from the switch connector receptacle. 11. Pull the left side of the cluster bezel away from the instrument panel far enough to access and disconnect the instrument panel wire harness connectors from the receptacles for the passenger airbag ON/OFF switch (if equipped), the rear window defogger switch (if equipped), the HVAC control, and the transfer case switch (if equipped). 12. Remove the cluster bezel from the instrument panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 5899 13. Remove the four screws that secure the HVAC control to the cluster bezel (Fig. 4). 14. Remove the HVAC control from the instrument panel. 15. Position the new HVAC control (see Parts Required section) in the cluster bezel and secure it with four screws. Tighten the screws to 2.2 Nm (17 i3 in. lbs.) 16. Position the cluster bezel to the instrument panel. 17. Pull the left side of the cluster bezel away from the instrument panel far enough to access and reconnect the instrument panel wire harness connectors to the receptacles for the passenger airbag on/off switch (if equipped), the rear window defogger switch (if equipped), the HVAC control, and the transfer case switch (if equipped). 18. Pull the right side of the cluster bezel away from the instrument panel far enough to access and reconnect the instrument panel wire harness connector for the headlamp switch to the switch connector receptacle. 19. Align the snap clips on the cluster bezel with the receptacles in the instrument panel base trim. 20. Using hand pressure, press firmly on the cluster bezel over each of the snap clip locations until each snap clip is fully engaged in their receptacle. 21. Install and tighten the two screws in the hooded area above the instrument cluster that secure the cluster bezel to the instrument panel base trim (Fig. 3). Tighten the screws to 2.2 Nm (20 in. lbs.). 22. Position the steering column opening cover to the instrument panel. 23. Align the snap clip retainers on the steering column opening cover with the receptacles in the instrument panel base trim. 24. Using hand pressure, press firmly on the steering column opening cover over the snap clip locations until each of the snap clips are fully engaged in their receptacle. 25. Install and tighten the three screws that secure the lower edge of the steering column opening cover to the instrument structural support. Tighten the screws to 2.2 Nm (20 in.lbs.). 26. Reach under the left end of the instrument panel to access and engage the park brake release link to the back of the handle. Then snap the rod end clip over the park brake release link to secure the connection. 27. Reconnect the battery negative cable. 28. On vehicles equipped with A/C, perform the A/C cool down test using the DRBIII(R). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 5900 Control Assembly: Locations The a/c heater control is located to the right of the instrument cluster on the instrument panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions Control Assembly: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5903 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5904 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5905 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5906 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5907 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5908 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5909 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5910 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5911 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5912 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5913 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5914 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5915 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5916 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5917 Control Assembly: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5918 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5919 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5920 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5921 Control Assembly: Connector Views A/C - Heater Control C1 Or Heater Control C1 A/C - Heater Control C2 Or Heater Control C2 A/C - Heater Control C3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5922 A/C - Heater Control C4 Rear A/C - Heater Control Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5923 Heating & A/C - Rear A/C - Heater Control Schematic Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 5924 Control Assembly: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application A/C Control .......................................................................................................................................... ..................................................................... 74 Heater Control .......................................................... ............................................................................................................................................... 158 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 5925 Control Assembly: Description and Operation Fig. 14 A/C Heater Control A/C HEATER CONTROL - FRONT The a/c heater control is a completely electronic control head. These controls provide the vehicle operator with a number of setting options to help control the climate and comfort within the vehicle. Refer to the owner's manual in the vehicle glove box for more information on the features, use, and suggested operation of these controls. The a/c heater control is located to the right of the instrument cluster on the instrument panel. The a/c heater control contains a rotary-type temperature control knob, a rotary-type mode control knob, a rotary-type blower motor speed knob, and push buttons for a/c compressor and rear window defogger/heated mirror operation. The a/c heater control is fully electronic, contains the logic and control circuits for the HVAC system, and is on the J1850 data bus. The a/c heater control cannot be repaired. If faulty or damaged, the entire unit must be replaced. The illumination lamps are available for service replacement. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 5926 Control Assembly: Testing and Inspection Satisfactory heater and air conditioner performance depends upon proper operation and adjustment of all operating controls and refrigeration system components. Use of the DRB-III is required for diagnosis and testing, follow instructions on DRB-III. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 5927 Control Assembly: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel from the instrument panel. Refer to: Instrument Panel, Gauges and Warning Indicators, Instrument Cluster Carrier, Service and Repair, Instrument Cluster Service Procedures, Instrument Cluster Bezel Replacement, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Procedures/Instrument Cluster Bezel Replacement Fig. 15 A/C Heater Control Remove/Install 3. Remove the four screws that secure the heater- A/C control to the cluster bezel. 4. Unplug the wire harness connector from the back of the heater-A/C control 5. Remove the heater-A/C control from the instrument panel. INSTALLATION 1. Plug the wire harness connector into the back of the heater-A/C control. 2. Position the heaterA/C control in the cluster bezel and secure it with four screws. Tighten the screws to 2.2 Nm (17 i3 in. lbs.). 3. Reinstall the cluster bezel to the instrument panel. Refer to: Instrument Panel, Gauges and Warning Indicators, Instrument Cluster Carrier, Service and Repair, Instrument Cluster Service Procedures, Instrument Cluster Bezel Replacement, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Procedures/Instrument Cluster Bezel Replacement 4. Connect the battery negative cable. 5. Perform the A/C cool down test using the DRB III. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Specifications Coupler HVAC: Specifications Intermediate Shaft Coupler Pinch Bolt ......................................................................................................................... 13.5 N.m (10 Ft. Lbs) (120 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Specifications > Page 5931 Coupler HVAC: Description and Operation REFRIGERANT LINE COUPLER - FRONT Spring-lock type refrigerant Line couplers are used to connect many of the refrigerant hues and other components to the refrigerant system. These couplers require a special tool for disengaging the two coupler halves. Fig. 4 Spring-Lock Coupler - Typical The spring-lock coupler is held together by a garter spring inside a circular cage on the male half of the fitting. When the two coupler halves are connected, the flared end of the female fitting slips behind the garter spring inside the cage on the male fitting. The garter spring and cage prevent the flared end of the female fitting from pulling out of the cage. Two O-rings on the male half of the fitting are used to seal the connection. These O-rings are compatible with R-134a refrigerant and must be replaced with O-rings made of the same material. Secondary clips are installed over the two connected coupler halves at the factory for added blowoff protection. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Specifications > Page 5932 Coupler HVAC: Service and Repair REMOVAL 1. Recover the refrigerant from the refrigerant system. 2. Remove the secondary clip from the spring-lock coupler. Fig. 5 Refrigerant Line Spring-Lock Coupler Disconnect 3. Fit the proper size A/C line disconnect tool (Special Tool Kit 7193) over the spring-lock coupler cage. 4. Close the two halves of the A/C line disconnect tool around the spring-lock coupler. 5. Push the A/C line disconnect tool into the open side of the coupler cage to expand the garter spring. Once the garter spring is expanded and while still pushing the disconnect tool into the open side of the coupler cage, pull on the refrigerant line attached to the female half of the coupler fitting until the flange on the female fitting is separated from the garter spring and cage on the male fitting within the disconnect tool. NOTE: The garter spring may not release if the A/C line disconnect tool is cocked while pushing it into the coupler cage opening. 6. Open and remove the A/C line disconnect tool from the disconnected spring-lock coupler. 7. Complete the separation of the two halves of the coupler fitting. INSTALLATION 1. Check to ensure that the garter spring is located within the cage of the male coupler fitting, and that the garter spring is not damaged. a. If the garter spring is missing, install a new spring by pushing it into the coupler cage opening. b. If the garter spring is damaged, remove it from the coupler cage with a small wire hook (DO NOT use a screwdriver) and install a new garter spring. 2. Clean any dirt or foreign material from both halves of the coupler fitting. 3. Install new O-rings on the male half of the coupler fitting. CAUTION: Use only the specified O-rings as they are made of a special material for the R-134a system. The use of any other O-rings may allow the connection to leak intermittently during vehicle operation. 4. Lubricate the male fitting and O-rings, and the inside of the female fitting with clean R-134a refrigerant oil. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 5. Fit the female half of the coupler fitting over the male half of the fitting. 6. Push together firmly on the two halves of the coupler fitting until the garter spring in the cage on the male half of the fitting snaps over the flanged end on the female half of the fitting. 7. Ensure that the spring-lock coupler is fully engaged by trying to separate the two coupler halves. This is done by pulling the refrigerant lines on either side of the coupler away from each other. 8. Reinstall the secondary clip over the spring- lock coupler cage. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 5941 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 5942 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 5943 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 5944 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 5945 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 5946 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 5947 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 5948 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 5949 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 5950 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 5951 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 5952 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 5958 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 5959 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 5960 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 5961 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 5962 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 5963 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 5964 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 5965 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 5966 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 5967 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 5968 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 5969 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 5970 Evaporator Core: Locations The front evaporator coil is located in the heater-A/C housing, under the instrument panel. The rear evaporator coil is located in the rear heater-A/C unit housing, in the right rear quarter panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 5971 Evaporator Core: Description and Operation A/C EVAPORATOR - FRONT The evaporator coil is located in the heater-A/C housing, under the instrument panel. The evaporator coil is positioned in the heater-A/C housing so that all air that enters the housing must pass over the fins of the evaporator before it is distributed through the system ducts and outlets. However, air passing over the evaporator coil fins will only be conditioned when the compressor is engaged and circulating refrigerant through the evaporator coil tubes. Refrigerant enters the evaporator from the expansion valve as a low-temperature, low-pressure mixture of liquid and gas. As air flows over the fins of the evaporator, the humidity in the air condenses on the fins, and the heat from the air is absorbed by the refrigerant. Heat absorption causes the refrigerant to boil and vaporize. The refrigerant becomes a low pressure gas when it leaves the evaporator. The evaporator coil cannot be repaired and, if faulty or damaged, it must be replaced. REAR EVAPORATOR The rear evaporator coil is located in the rear heater-A/C unit housing, in the right rear quarter panel. The evaporator coil is positioned in the heater-A/C unit housing so that all air that enters the housing must pass over the fins of the evaporator before it is distributed through the system outlets. However, air passing over the evaporator coil fins will only be conditioned when the compressor is engaged and circulating refrigerant through the evaporator coil tubes. Refrigerant enters the evaporator from the rear expansion valve as a low-temperature, low pressure mixture of liquid and gas. As air flows over the fins of the evaporator, the humidity in the air condenses on the fins, and the heat from the air is absorbed by the refrigerant. Heat absorption causes the refrigerant to boil and vaporize. The refrigerant becomes a low-pressure gas when it leaves the evaporator. The rear evaporator coil cannot be repaired and, if faulty or damaged, the rear evaporator coil must be replaced. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front A/C Evaporator Evaporator Core: Service and Repair Front A/C Evaporator REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the heater-A/C housing from the vehicle, and remove the housing cover. Refer to: Heating and Air Conditioning, Housing Assembly HVAC, Service and Repair, Front, Front HVAC Unit Removal and Installation, See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Front HVAC Housing Removal and Installation 3. Lift the front evaporator coil out of the heater- A/C housing. INSTALLATION 1. Insert the front evaporator coil into the bottom of the heater-A/C housing. 2. Reassemble and reinstall the heater-A/C housing in the vehicle. Refer to: Heating and Air Conditioning, Housing Assembly HVAC, Service and Repair, Front, Front HVAC Unit Removal and Installation, See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Front HVAC Housing Removal and Installation NOTE: If the front evaporator coil is replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 3. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Evacuate, See: Refrigerant/Service and Repair/Refrigerant - Evacuate 4. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Charge, See: Refrigerant/Service and Repair/Refrigerant - Charge 5. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front A/C Evaporator > Page 5974 Evaporator Core: Service and Repair Rear Evaporator REMOVAL 1. Disconnect the negative battery cable and isolate it. 2. Discharge the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Recovery, See: Refrigerant/Service and Repair/Refrigerant - Recovery 3. Remove the right rear trim panel. 4. Remove the heater-A/C assembly. Refer to: Heating and Air Conditioning, Housing Assembly HVAC, Service and Repair, Rear, Rear HVAC Unit Removal and Installation, See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Rear HVAC Housing Removal and Installation 5. Place the heater-A/C unit on a work bench. 6. Remove the three mode door actuator retainer screws. 7. Remove the mode door actuator from the heater-A/C unit and set aside. 8. Remove all screws and clips that hold the heater-A/C unit case together. 9. Separate the heater-A/C case halves. 10. Remove the evaporator core from the heater- A/C housing. INSTALLATION 1. Install the evaporator core into the heater-A/C housing. 2. Place the two heater-A/C case halves together, making sure all seals are in place. Replace any damaged case seals. 3. Install all screws and clips that hold the heater-A/C housing together. 4. Install the mode door actuator to the heaterA/C housing. 5. Install the three mode door actuator retainer screws. 6. Take the heater-A/C unit from the work bench and place in the rear of the vehicle. 7. Install the heater-A/C housing into the vehicle. Refer to: Heating and Air Conditioning, Housing Assembly HVAC, Service and Repair, Rear, Rear HVAC Unit Removal and Installation, See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Rear HVAC Housing Removal and Installation 8. Install the right rear trim panel. 9. Evacuate the heater-A/C unit. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Evacuate, See: Refrigerant/Service and Repair/Refrigerant - Evacuate 10. Recharge the heater-A/C unit. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Charge, See: Refrigerant/Service and Repair/Refrigerant - Charge 11. Install the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 23-010-04A > Sep > 04 > A/C - Water Leaks Onto Passenger Front Floor Evaporator Drain Tube: Customer Interest A/C - Water Leaks Onto Passenger Front Floor NUMBER: 23-010-04 REV. A GROUP: Body DATE: September 9, 2004 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-010-04, DATED APRIL 29, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL MODELS AND REVISED LABOR OPERATIONS. SUBJECT: Passenger Compartment Floor Water Leak OVERVIEW: This bulletin involves sealing the opening for the evaporator hose/drain tube with RTV sealer. MODELS: 2001-2004 (AN) Dakota **2004 - 2005 (CS) Pacifica** 2001 - 2003 (DN) Durango **2002 - 2005 (KJ) Cherokee (International Markets)** 2001 - 2004 (RS) Caravan, Voyager, Town & Country NOTE: **This bulletin applies to KJ vehicles that are Right Hand Drive (RHD).** SYMPTOM/CONDITION: Water may enter the passenger compartment between the HVAC housing and the bulkhead. A foam seal is used to seal the heater housing to the bulkhead. Condensation from the A/C evaporator can run along the evaporator drain tube and enter the passenger compartment if the seal between the HVAC housing and the bulkhead is not sealed properly. This will result in wet passenger compartment carpet when the air conditioning is operating. DIAGNOSIS: If the symptom exists, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Locate the evaporator hose and drain tube opening in bulkhead at the rear of the engine compartment. Apply a bead of RTV sealer, p/n 04467708 or equivalent, to the perimeter of the opening to seal the joint between the bulkhead and the HVAC gasket and the joint between the drain tube and the HVAC gasket. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 23-010-04A > Sep > 04 > A/C - Water Leaks Onto Passenger Front Floor > Page 5983 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 11-002-01 > Sep > 01 > Evaporator Drain/Exhaust Hissing Sound Evaporator Drain Tube: Customer Interest Evaporator Drain/Exhaust - Hissing Sound NUMBER: 11-002-01 GROUP: Exhaust DATE: Sept. 14, 2001 SUBJECT: Hissing Sound When Water From The Evaporator Drain Drips On Exhaust OVERVIEW: This bulletin involves installing a revised exhaust system heat shield containing a drain trough to route water away from the exhaust system. MODELS: 2001 (AN) Dakota 2001 (DN) Durango SYMPTOM/CONDITION: A hissing sound may be present when water from the A/C evaporator drain drips onto the exhaust system. DIAGNOSIS: If the condition is present or the customer indicates that the vehicle exhibits the condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. WARNING: THE ENGINE AND EXHAUST SYSTEM MAY BE EXTREMELY HOT. ALLOW SUFFICIENT TIME FOR THE ENGINE AND EXHAUST SYSTEM TO COOL PRIOR TO PERFORMING THIS PROCEDURE. 1. Locate the heat shield in the engine compartment directly above the right side exhaust manifold to front exhaust pipe connection. 2. Remove the two screws attaching the heat shield to the bulkhead and remove the shield. Discard the shield. 3. Install the new shield, P/N 55257336AB, with the drain trough located at the top. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 11-002-01 > Sep > 01 > Evaporator Drain/Exhaust Hissing Sound > Page 5988 FAILURE CODE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 23-010-04A > Sep > 04 > A/C - Water Leaks Onto Passenger Front Floor Evaporator Drain Tube: All Technical Service Bulletins A/C - Water Leaks Onto Passenger Front Floor NUMBER: 23-010-04 REV. A GROUP: Body DATE: September 9, 2004 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-010-04, DATED APRIL 29, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL MODELS AND REVISED LABOR OPERATIONS. SUBJECT: Passenger Compartment Floor Water Leak OVERVIEW: This bulletin involves sealing the opening for the evaporator hose/drain tube with RTV sealer. MODELS: 2001-2004 (AN) Dakota **2004 - 2005 (CS) Pacifica** 2001 - 2003 (DN) Durango **2002 - 2005 (KJ) Cherokee (International Markets)** 2001 - 2004 (RS) Caravan, Voyager, Town & Country NOTE: **This bulletin applies to KJ vehicles that are Right Hand Drive (RHD).** SYMPTOM/CONDITION: Water may enter the passenger compartment between the HVAC housing and the bulkhead. A foam seal is used to seal the heater housing to the bulkhead. Condensation from the A/C evaporator can run along the evaporator drain tube and enter the passenger compartment if the seal between the HVAC housing and the bulkhead is not sealed properly. This will result in wet passenger compartment carpet when the air conditioning is operating. DIAGNOSIS: If the symptom exists, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Locate the evaporator hose and drain tube opening in bulkhead at the rear of the engine compartment. Apply a bead of RTV sealer, p/n 04467708 or equivalent, to the perimeter of the opening to seal the joint between the bulkhead and the HVAC gasket and the joint between the drain tube and the HVAC gasket. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 23-010-04A > Sep > 04 > A/C - Water Leaks Onto Passenger Front Floor > Page 5994 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 11-002-01 > Sep > 01 > Evaporator Drain/Exhaust - Hissing Sound Evaporator Drain Tube: All Technical Service Bulletins Evaporator Drain/Exhaust - Hissing Sound NUMBER: 11-002-01 GROUP: Exhaust DATE: Sept. 14, 2001 SUBJECT: Hissing Sound When Water From The Evaporator Drain Drips On Exhaust OVERVIEW: This bulletin involves installing a revised exhaust system heat shield containing a drain trough to route water away from the exhaust system. MODELS: 2001 (AN) Dakota 2001 (DN) Durango SYMPTOM/CONDITION: A hissing sound may be present when water from the A/C evaporator drain drips onto the exhaust system. DIAGNOSIS: If the condition is present or the customer indicates that the vehicle exhibits the condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. WARNING: THE ENGINE AND EXHAUST SYSTEM MAY BE EXTREMELY HOT. ALLOW SUFFICIENT TIME FOR THE ENGINE AND EXHAUST SYSTEM TO COOL PRIOR TO PERFORMING THIS PROCEDURE. 1. Locate the heat shield in the engine compartment directly above the right side exhaust manifold to front exhaust pipe connection. 2. Remove the two screws attaching the heat shield to the bulkhead and remove the shield. Discard the shield. 3. Install the new shield, P/N 55257336AB, with the drain trough located at the top. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 11-002-01 > Sep > 01 > Evaporator Drain/Exhaust - Hissing Sound > Page 5999 FAILURE CODE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams Evaporator Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Locations Expansion Valve: Locations The front "H" valve-type Thermal Expansion Valve (TXV) is located at the dash panel between the liquid and suction lines, and the evaporator coil. The rear A/C unit have an H-type thermal expansion valve (TXV) located on the rear HVAC unit, behind the passenger side rear quarter trim panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Locations > Page 6006 Expansion Valve: Description and Operation A/C EXPANSION VALVE - FRONT The front "H" valve-type Thermal Expansion Valve (TXV) is located at the dash panel between the liquid and suction lines, and the evaporator coil. High-pressure, high temperature liquid refrigerant from the liquid line passes through the expansion valve orifice, converting it into a low-pressure, low-temperature mixture of liquid and gas before it enters the evaporator coil. The expansion valve control head monitors the temperature and pressure of the refrigerant leaving the evaporator coil through the suction line, and adjusts the orifice size at the liquid line to let the proper amount of refrigerant into the evaporator coil to meet the vehicle cooling requirements. Controlling the refrigerant flow through the evaporator ensures that none of the refrigerant leaving the evaporator is still in a liquid state, which could damage the compressor. The expansion valve is a factory calibrated unit and cannot be adjusted or repaired. If faulty or damaged, the expansion valve must be replaced. REAR EXPANSION VALVE Vehicles equipped with the optional rear A/C unit have an H-type thermal expansion valve (TXV) located on the rear HVAC unit, behind the passenger side rear quarter trim panel. It performs the same function as the front expansion valve, to monitor refrigerant temperature and pressure at the control head and meter the refrigerant entering the evaporator to meet the vehicle cooling requirements. The rear expansion valve is a factory calibrated unit and cannot be adjusted or repaired. If faulty or damaged, the rear expansion valve unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Locations > Page 6007 Expansion Valve: Testing and Inspection These tests must be made at an ambient temperature of 21 to 29 °C (70 to 85 °F). Disconnect the wire connector at the low pressure cut off switch. Use a jumper wire to jumper terminals at the connector. Front (Only) 1. Attach a manifold gauge set or an approved A/C Recharging/Recycling Station. Close the vehicle doors and windows, start the engine, and hold the engine speed at 1,000 rpm. Set the heater-A/C mode control switch knob to the recirculation mode (Max A/C) position, the temperature control knob to the full hot position, and the blower motor switch to the highest speed position. 2. Operate the air conditioning system for at least five minutes to stabilize the system, and to provide sufficient reheat to load the evaporator. The discharge pressure (high side) at the service port should reach 966 to 1656 kPa (140 to 240 psi). If this discharge pressure cannot be obtained, check the refrigerant system charge. WARNING: EXTREME CARE MUST BE USED WHEN HANDLING LIQUID CARBON DIOXIDE (CO), AS SKIN INJURY CAN OCCUR. PROTECTIVE GLOVES SHOULD BE WORN. 3. Apply liquid Carbon Dioxide (CO) to the expansion valve control head (completely cover the head) for a minimum of thirty seconds. Observe the manifold gauge set. The suction pressure (low side) must drop to below 50 kPa (7.25 psi). If this reading is not obtained, the expansion valve is faulty and must be replaced. 4. Remove the liquid carbon dioxide (CO) from the control head. Observe the manifold gauge set. The suction pressure (low side) must increase to a minimum of 262 kPa (38 psi), and then stabilize to a pressure of 172 to 240 kPa (25 to 35 psi). If these readings are not obtained, the expansion valve is faulty and must be replaced. 5. Set the engine idle speed at 1,000 rpm and the blower motor switch to the highest speed position. The suction pressure (low side) should be 138 to 207kPa (20 to 30 psi). If the discharge pressure (high side) is higher than 1656 kPa (240 psi), check for a restricted discharge line. Also check the engine cooling system for overheating, air trapped in the system, or a faulty fan drive. If the discharge pressure (high side) is less than 966 kPa (140 psi), check for a faulty compressor. Front And Rear A/C 1. Attach a manifold gauge set or an approved A/C Recharging/Recycling Station. Close the vehicle doors and windows, start the engine, and hold the engine speed at 1,000 rpm. Set the heater-A/C mode control switch knob to the recirculation mode (Max A/C) position, the temperature control knob to the full hot position, and both the front and rear blower motor switches to their highest speed positions. 2. Operate the air conditioning system for at least five minutes to stabilize the system, and to provide sufficient reheat to load the front and rear evaporators. The discharge pressure (high side) at the service port should reach 966 to 1656 kPa (140 to 240 psi). If this discharge pressure cannot be obtained, check the refrigerant system charge. See Refrigerant System Charge in the Service Procedures. WARNING: EXTREME CARE MUST BE USED WHEN HANDLING LIQUID CARBON DIOXIDE (CO) AS SKIN INJURY CAN OCCUR. PROTECTIVE GLOVES SHOULD BE WORN. 3. Both the front and rear expansion valves should be checked for correct operation. Apply liquid carbon dioxide (CO) to the front expansion valve control head (completely cover the head) for a minimum of thirty seconds. Observe the manifold gauge set. The suction pressure (low side) must drop to below 50 kPa (7.25 psi). If this reading is not obtained, the expansion valve is faulty and must be replaced. 4. Apply liquid carbon dioxide (CO) to the front expansion valve control head (completely cover the head) for a minimum of thirty seconds. Remove the protective cover and apply liquid carbon dioxide (CO) to the rear expansion valve control head. Grasp the suction line (large line) off the evaporator with a bare hand and hold it for at least two minutes. Use the same procedure with the front expansion valve. Grasp the suction line jumper below the expansion valve (before the rear suction line tee) with a bare hand and hold for at least two minutes. When testing the front expansion valve, place the rear blower motor switch in the OFF position. 5. With a correctly operating expansion valve, the suction line will feel warm with the closing of the valve (cold applied). Then the line will cool sharply within two minutes as the valve opens. If this temperature change does not occur, the expansion valve is faulty and must be replaced. Front Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > Front Expansion Valve: Service and Repair Front REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 3. Remove the liquid line from the engine compartment. Fig.3 Expansion Valve Remove/Install 4. Remove the two screws that secure the expansion valve to the evaporator tube mounting flange. 5. Remove the expansion valve from the evaporator tube mounting flange. Install plugs in, or tape over all of the opened refrigerant line fittings. INSTALLATION 1. Install the expansion valve to the evaporator tube mounting flange. (Remove all plugs or tape covering connections) 2. Install the two screws that secure the expansion valve to the evaporator tube mounting flange. 3. Install the liquid line to the engine compartment. 4. Evacuate the refrigerant system. 5. Recharge the refrigerant system. 6. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > Front > Page 6010 Expansion Valve: Service and Repair Rear REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 3. Remove the rear inside trim panel. Fig.1 Rear Expansion Valve Removal/Install 4. Disassemble the two bolts attaching the expansion valve. Install plugs in, or tape over the open refrigerant fittings. INSTALLATION 1. Install the expansion valve to the evaporator tube mounting flange. (Remove all plugs or tape covering connections). 2. Install the two screws that secure the expansion valve to the evaporator tube mounting flange. 3. Evacuate the refrigerant system. 4. Recharge the refrigerant system. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Locations Heater Core: Locations The front heater core is located in the HVAC housing, under the instrument panel. The rear heater core is located in the heater-A/C housing in the right rear inside quarter panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Locations > Page 6014 Heater Core: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Locations > Page 6015 Heater Core: Description and Operation HEATER CORE - FRONT The heater core is located in the HVAC housing, under the instrument panel. It is a heat exchanger made of rows of tubes and fins. The heater core is not repairable and if damaged it must be replaced. Engine coolant is circulated through heater hoses to the heater core at all times. As the coolant flows through the heater core, heat removed from the engine is transferred to the heater core fins and tubes. Air directed through the heater core picks up the heat from the heater core fins. The blend door allows control of the heater output air temperature by controlling how much of the air flowing through the HVAC housing is directed through the heater core. The blower motor speed controls the volume of air flowing through the HVAC housing. The heater core cannot be repaired and, if faulty or damaged, it must be replaced. REAR HEATER CORE The rear heater core is located in the heater-A/C housing in the right rear inside quarter panel. It is a heat exchanger made of rows of tubes and fins. The heater core is not repairable and if damaged it must be replaced. Engine coolant is circulated through heater hoses/tubes to the heater core at all times. As the coolant flows through the heater core, heat removed from the engine is transferred to the heater core fins and tubes. Air directed through the heater core picks up the heat from the heater core fins. The blend air door allows control of the heater output air temperature by controlling how much of the air flowing through the heater-A/C housing is directed through the heater core. The blower motor speed controls the volume of air flowing through the heater-A/C housing. The heater core cannot be repaired and, if faulty or damaged, it must be replaced. Refer to Cooling System for more information on the engine cooling system, the engine coolant and the heater hoses. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Front Heater Core: Service and Repair Front REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Drain to cooling systems. 2. Remove the heater-A/C housing from the vehicle. Refer to: Heating and Air Conditioning, Housing Assembly HVAC, Service and Repair, Front, Front HVAC Unit Removal and Installation, See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Front HVAC Housing Removal and Installation 3. Disassemble the HVAC housing to access the heater core. 4. Lift the heater core out of the heater-A/C housing. INSTALLATION 1. Insert the heater core into the bottom of the heater-A/C housing. 2. Reassemble the heater-A/C housing. 3. Install the heater-A/C housing into the vehicle. Refer to: Heating and Air Conditioning, Housing Assembly HVAC, Service and Repair, Front, Front HVAC Unit Removal and Installation, See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Front HVAC Housing Removal and Installation 4. Refill the cooling system. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Front > Page 6018 Heater Core: Service and Repair Rear REMOVAL 1. Remove the rear trim cover. 2. Remove the three blend door actuator screws. 3. Remove the blend door actuator and place aside. Refer to: "Air Door: Air Door Actuator-Motor" See: Air Door/Air Door Actuator / Motor 4. Remove the two screws from the heater/evaporator tubes plastic retainer. 5. Remove the heater core from the case. INSTALLATION 1. Install the heater core into the heater-A/C housing. 2. Install the two screws to the heater/evaporator tubes plastic retainer. 3. Install the blend door actuator. Refer to: "Air Door: Air Door Actuator-Motor" See: Air Door/Air Door Actuator / Motor 4. Install the three blend door actuator screws. 5. Install the rear trim cover. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation High Pressure Safety Valve HVAC: Description and Operation A/C COMPRESSOR HIGH PRESSURE RELIEF VALVE - FORNT A high pressure relief valve is located on the compressor cylinder head, which is at the rear of the compressor. This mechanical valve is designed to vent refrigerant from the system to protect against damage to the compressor and other system components, caused by condenser air flow restriction or an overcharge of refrigerant. The high pressure relief valve vents the system when a discharge pressure of 3445 to 4135 kPa (500 to 600 psi) or above is reached. The valve closes with a minimum discharge pressure of 2756 kPa (400 psi) is reached. The high pressure relief valve vents only enough refrigerant to reduce the system pressure, and then re-seats itself. The majority of the refrigerant is conserved in the system. If the valve vents refrigerant, it does not mean the valve is faulty. The high pressure relief valve is a factory-calibrated unit. The valve cannot be adjusted or repaired, and must not be removed or otherwise disturbed. The valve is only serviced as a part of the compressor assembly. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications Hose/Line HVAC: Specifications Refrigerant Lines at Compressor ............................................................................................................................. 23 N.m (17 Ft. Lbs) (200 ± 30 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications > Page 6025 Hose/Line HVAC: Service Precautions Kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire system. High pressures are produced in the system when it is operating. Extreme care must be exercised to make sure that all refrigerant system connections are pressure tight. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. Sharp bends will reduce the flow of refrigerant. The flexible hose lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. It is a good practice to inspect all flexible refrigerant system hose lines at least once a year to make sure they are in good condition and properly routed. There are two types of refrigerant fittings: - All fittings with O-rings need to be coated with refrigerant oil before installation. Use only O-rings that are the correct size and approved for use with R-134a refrigerant. Failure to do so may result in a leak. - Unified plumbing connections with gaskets cannot be serviced with O-rings. The gaskets are not reusable and new gaskets do not require lubrication before installing. Using the proper tools when making a refrigerant plumbing connection is very important. Improper tools or improper use of the tools can damage the refrigerant fittings. The refrigerant must be recovered completely from the system before opening any fitting or connection. Open the fittings with caution, even after the refrigerant has been recovered. If any pressure is noticed as a fitting is loosened, tighten the fitting and recover the refrigerant from the system again. Do not discharge refrigerant into the atmosphere. Use an R-134a refrigerant recovery/recycling device that meets SAE Standard J2210. The refrigerant system will remain chemically stable as long as pure, moisture-free R-134a refrigerant and refrigerant oil is used. Dirt, moisture, or air can upset this chemical stability. Operational troubles or serious damage can occur if foreign material is present in the refrigerant system. When it is necessary to open the refrigerant system, have everything needed to service the system ready. The refrigerant system should not be left open to the atmosphere any longer than necessary. Cap or plug all lines and fittings as soon as they are opened to prevent the entrance of dirt and moisture. All lines and components in parts stock should be capped or sealed until they are to be installed. All tools, including the refrigerant recycling equipment, the manifold gauge set, and test hoses should be kept clean and dry. All tools and equipment must be designed for R-134a refrigerant. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications > Page 6026 Hose/Line HVAC: Description and Operation REFRIGERANT LINES The refrigerant lines and hoses are used to carry the refrigerant between the various air conditioning system components. A barrier hose design with a nylon tube, which is sandwiched between rubber layers, is used for the R-134a air conditioning system on this vehicle. This nylon tube helps to further contain the R-134a refrigerant, which has a smaller molecular structure than R-12 refrigerant. The ends of the refrigerant hoses are made from lightweight aluminum or steel, and commonly use braze-less fittings. Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. The refrigerant lines and hoses are coupled with other components of the HVAC system with peanut-block style fittings. A stat-O seal type flat steel gasket with a captured compressible O-ring, is used to mate plumbing lines with A/C components to ensure the integrity of the refrigerant system. The refrigerant lines and hoses cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant Recovery, See: Refrigerant/Service and Repair/Refrigerant - Recovery 3. Disconnect the refrigerant line at the condenser and the suction line jumper. 4. Remove the screw that secures the refrigerant line manifold to the compressor. Install plugs in, or tape over all of the opened refrigerant line fittings 5. Remove the discharge line assembly from the vehicle. INSTALLATION 1. Install the discharge line assembly to the vehicle. Remove all plugs or tape installed over line connections. 2. Install the screw that secures the refrigerant line manifold to the compressor. Tighten the screw to 22 Nm (200 ± 30 in. lbs.). 3. Connect the refrigerant line at the condenser and the suction line jumper. Tighten to 22 Nm (300 ± 30 in. lbs.) 4. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Evacuate, See: Refrigerant/Service and Repair/Refrigerant - Evacuate 5. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Charge, See: Refrigerant/Service and Repair/Refrigerant - Charge 7. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 6029 Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Replacement REMOVAL Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant Recovery, See: Refrigerant/Service and Repair/Refrigerant - Recovery 3. Remove the screw that secures the front liquid line block fitting to the inlet of the filter-drier, and disengage the fitting from the filter-drier. Install plugs in, or tape over all of the opened refrigerant line fittings. 4. Disconnect the front liquid line refrigerant line coupler at the condenser outlet. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the front liquid line from the engine compartment. 6. Disconnect the wiring connector from the Pressure Transducer on the rear liquid line. 7. Remove the screw that secures the rear liquid line to the outlet of the filter-drier and disengage the fitting from the filter-drier. Install plugs or tape over the opened refrigerant line fittings. 8. Remove the screw from the rear liquid line fitting at the expansion valve. Plug or tape over the opened refrigerant line fittings. 9. Remove the rear liquid line from the vehicle. INSTALLATION Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. 1. Remove the tape or plugs from the refrigerant line fittings on the front liquid line and the condenser outlet. Connect the front liquid line to the condenser outlet. 2. Remove the tape or plugs from the front liquid line block fitting and the filter-drier inlet. Install the front liquid line block fitting to the filter-drier inlet and secure the connection with a screw. Tighten the mounting screw to 13.5 Nm (120 in. lbs.). 3. Install the rear liquid line into the vehicle. 4. Remove any plugs or tape installed over the connections. 5. Install the rear liquid line to the expansion valve. 6. Install the rear liquid line to the filter-drier and secure the screw. Tighten the screw to 13.5 Nm (120 in. lbs.). 7. Connect the wiring connector to the Pressure Transducer on the rear liquid line. 8. Connect the battery negative cable. 9. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Evacuate, See: Refrigerant/Service and Repair/Refrigerant - Evacuate 10. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Charge, See: Refrigerant/Service and Repair/Refrigerant - Charge Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 6030 Hose/Line HVAC: Service and Repair A/C Suction Hose/Line Replacement REMOVAL Suction line Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant Recovery, See: Refrigerant/Service and Repair/Refrigerant - Recovery 3. Disconnect the refrigerant line block fitting at the condenser and the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings. 4. Remove the screw that secures the refrigerant line manifold to the compressor. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the suction and discharge line assembly from the vehicle. Suction Line Jumper Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant. system connections is pressure-tight and leak free. 1. Disconnect and isolate the battery negative cable. 2. Remove the low pressure cut-off switch from the fitting on the suction line jumper. 3. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant Recovery, See: Refrigerant/Service and Repair/Refrigerant - Recovery 4. Disconnect the refrigerant line coupler between the suction line and the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the liquid line from the engine compartment. 6. Slide the plastic retainer that secures the suction line jumper out of the saddle formation at the top of the rear liquid line block fitting. Secure block, preferably in a vise. Tap the plastic retainer out with a hammer and flat-bladed screwdriver. 7. Remove the suction line jumper from the rear liquid line block fitting. INSTALLATION Suction line 1. Remove the tape or plugs from all of the refrigerant line fittings. Install the refrigerant line couplers to the suction line jumper. 2. Install the discharge line to the condenser. Tighten the screws to 22 Nm ( 200 ± 30 in. lbs.) 3. Install the refrigerant line manifold to the compressor. Tighten the mounting screw to 22 Nm (200 ± 30 in. lbs.). 4. Connect the battery negative cable. 5. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant, Refrigerant Evacuate, See: Refrigerant/Service and Repair/Refrigerant - Evacuate 6. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Charge, See: Refrigerant/Service and Repair/Refrigerant - Charge Suction Line Jumper Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. 1. Using a new O-ring, install the suction line jumper into the saddle formation at the top of the rear liquid line block fitting. 2. Slide the plastic retainer that secures the suction line jumper into the rear liquid line block fitting. 3. Install the rear liquid line into the engine compartment. 4. Remove the tape or plugs from the refrigerant line fittings on the suction line and the suction line jumper. Install the suction line to the suction line jumper. 5. Install the low pressure cut-off switch to the fitting on the suction line jumper. 6. Connect the battery negative cable. 7. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant, Refrigerant Evacuate, See: Refrigerant/Service and Repair/Refrigerant - Evacuate Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 6031 8. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Charge, See: Refrigerant/Service and Repair/Refrigerant - Charge Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 6032 Hose/Line HVAC: Service and Repair Rear Underbody A/C Lines Replacement REMOVAL Complete Rear A/C Line 1. Reclaim the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant Recovery, See: Refrigerant/Service and Repair/Refrigerant - Recovery 2. Remove air box. 3. Lift vehicle on hoist. 4. Remove passenger side tires. 5. Remove front and rear inner fenders. 6. Disconnect the front underhood a/c line. 7. Disconnect the underbody a/c line assembly at the rear HVAC unit. 8. Remove all body mount bolts on the passenger side and loosen the body mount bolts on the drivers side. 9. Place a jack stand at the front and rear of the vehicle on the passenger side so that the stands will support the body. 10. Detach all underbody a/c assembly brackets from the body that are accessible. 11. Lower the hoist until the body, that is being supported by the stands, is approximately 3-4 inches above the frame. This will allow access to the underbody assembly. 12. Remove all remaining a/c line brackets that were not accessible before the body lift. 13. Remove the complete a/c line assembly from the vehicle. 5/8" Front A/C Tube Repair 1. Discharge and recover refrigerant from a/c system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant Recovery, See: Refrigerant/Service and Repair/Refrigerant - Recovery 2. Remove air box. 3. Lift vehicle on hoist. 4. Remove passenger side front tire. 5. Remove passenger side front inner fender well. 6. Disconnect suction line spring lock from suction jumper. 7. Remove and under side brackets as necessary. 8. Mark cut location on the tube on the vehicle. 9. Cut tube on truck. 10. Size replacement tube, same as tube removed from truck. 11. Scuff end of both tubes using pad provided with special tool kit. 12. Select proper Lokring for (5/8") tube. 13. Put a drop of sealer from kit on the end of each tube, install Lokring and rotate to spread sealer evenly. 14. Select the proper jaws for the installation tool (5/8") from the special tool kit. 15. Put installation tool over the Lokring with tubes installed. 16. Compress Lokring using a wrench to draw the screw tight on the installation tool. Tighten the tool until the Lokring is bottomed out. 17. Back off the screw and remove the installation tool. 18. Reconnect the suction line spring lock. 19. Reinstall the passenger side front inner fender well. 20. Install the passenger side tire. 21. Lower the vehicle on the hoist. 22. Reinstall the air box. 23. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Evacuate, See: Refrigerant/Service and Repair/Refrigerant - Evacuate 24. Recharge the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Charge, See: Refrigerant/Service and Repair/Refrigerant - Charge 3/8" Front A/C Tube Repair 1. Discharge and reclaim the a/c refrigerant. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Recovery, See: Refrigerant/Service and Repair/Refrigerant - Recovery 2. Remove the air box. 3. Lift vehicle on an approved hoist. 4. Remove the passenger front tire. 5. Remove the passenger side front inner fender well. 6. Disconnect the liquid line spring lock from the suction jumper. 7. Remove under brackets as necessary. 8. Mark cut location on tube on vehicle. 9. Cut tube on vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 6033 10. Size replacement tube, same as tube removed from truck. 11. Scuff end of both tubes using pad provided in special tool kit. 12. Select proper Lokring for (3/8") tube. 13. Put a drop of sealer from kit on the end of each tube, install Lokring and rotate to spread sealer evenly. 14. Select the proper jaws for the installation tool (3/8") from the kit. 15. Put installation tool over the Lokring with tubes installed. 16. Compress Lokring using a wrench to draw the screw tight on the installation tool. Tighten the tool until the Lokring is bottomed out. 17. Back off the screw and remove the installation tool. 18. Reconnect the liquid line spring lock. 19. Reinstall the passenger side inner wheel well. 20. Reinstall the passenger side wheel. 21. Lower the vehicle on the hoist. 22. Reinstall the air box. 23. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Evacuate, See: Refrigerant/Service and Repair/Refrigerant - Evacuate 24. Recharge the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Charge, See: Refrigerant/Service and Repair/Refrigerant - Charge 5/8" Rear A/C Tube Repair 1. Recover the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Refrigerant - Recovery, See: Refrigerant/Service and Repair/Refrigerant - Recovery 2. Lift the vehicle on an approved hoist. 3. Remove the passenger side rear tire. 4. Remove the passenger side rear inner fender well. 5. Disconnect the rear a/c lines from the rear evaporator. 6. Mark cut location on tube on vehicle. 7. Cut tube on truck. 8. Size replacement tube, same as tube removed from truck. 9. Scuff end of both tubes using pad provide in special tool kit. 10. Select proper Lokring for 5/8" tube. 11. Put a drop of sealer from kit on the end of each tube, install Lokring and rotate to spread sealer evenly. 12. Select the proper jaws for the installation tool (5/8") from the kit. 13. Put installation tool over the Lokring with tubes installed (tubes must be bottomed out in Lokring). 14. Compress Lokring using a wrench to draw the screw tight on the installation tool. Tighten the tool until the Lokring is bottomed out. 15. Backoff the screw and remove the installation tool. 16. Reconnect the rear evaporator. 17. Install the passenger side inner fender. 18. Install the passenger side tire. 19. Lower the vehicle. 20. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant Evacuate, See: Refrigerant/Service and Repair/Refrigerant - Evacuate 21. Recharge the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Charge, See: Refrigerant/Service and Repair/Refrigerant - Charge 3/8" Rear A/C Tube Repair 1. Evacuate and recover the refrigerant from the a/c system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Recovery, See: Refrigerant/Service and Repair/Refrigerant - Recovery 2. Lift vehicle on an approved hoist. 3. Remove the rear passenger side tire. 4. Remove the rear passenger side inner wheel well. 5. Disconnect the rear a/c line from the rear evaporator. 6. Mark cut location on tube on vehicle. 7. Cut tube on truck. 8. Size replacement tube, same as tube removed from the truck. 9. Scuff end of both tubes using pad provide in special tool kit. 10. Select proper Lokring for 3/8" tube. 11. Put a drop of sealer from kit on the end of each tube, install Lokring and rotate to spread sealer evenly. 12. Select the proper jaws for the installation tool (3/8") from the special tool kit. 13. Put installation tool over the Lokring with tubes installed. 14. Compress Lokring using a wrench to draw the screw tight on the installation tool. Tighten the tool until the Lokring is bottomed out. 15. Back off the screw and remove the installation tool. 16. Reconnect the rear evaporator. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 6034 17. Install the passenger side inner fender well. 18. Install the passenger side rear tire. 19. Lower the vehicle from the hoist. 20. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Evacuate, See: Refrigerant/Service and Repair/Refrigerant - Evacuate 21. Recharge the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Charge, See: Refrigerant/Service and Repair/Refrigerant - Charge INSTALLATION Complete Rear A/C Line 1. Install the complete a/c line assembly into the vehicle. 2. Install the a/c line brackets that will not be accessible once body is lowered onto frame. 3. Raise the hoist until the frame and body are lined up and the body mounts line up with the frame mounting pieces. 4. Install all remaining underbody a/c line assembly brackets. 5. Install all body mount bolts on the passenger side and tighten both passenger and drive side mount bolts. 6. Raise the lift until the jack stands are free, then remove the jack stands from under the vehicle. 7. Connect the underbody a/c lines at the rear HVAC unit. 8. Connect the front a/c lines in the engine compartment. 9. Install the front and rear inner fenders. 10. Install passenger side tires. 11. Lower vehicle on lift. 12. Install air box. 13. Evacuate refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant Evacuate, See: Refrigerant/Service and Repair/Refrigerant - Evacuate 14. Charge refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Charge, See: Refrigerant/Service and Repair/Refrigerant - Charge Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 6035 Hose/Line HVAC: Service and Repair Rear Underbody Heater Lines Replacement REMOVAL 1/2" Front Heater Tube Repair 1. Pinch hoses in engine compartment using spring clamp pliers. 2. Remove air box. 3. Remove passenger front tire. 4. Remove front inner fender well. 5. Disconnect the heater hose from underbody heater line using constant tension clamp pliers. 6. Drain coolant from underbody heater lines into an approved container. 7. Remove line brackets as necessary. 8. Mark cut location on tube on vehicle. 9. Cut tube on vehicle. 10. Size replacement tube, same as tube removed from vehicle. 11. Scuff end of both tubes using pad provided in special tool kit. 12. Select proper Lokring for 1/2" tube. 13. Put a drop of sealer from kit in the end of each tube, install Lokring and rotate to spread sealer evenly. 14. Select the proper jaws for the installation tool 1/2" from the kit. 15. Put installation tool over the Lokring with tubes installed (tube must be bottomed out in Lokring). 16. Compress Lokring using a wrench to draw the screw tight on the installation tool. Tighten the tool until the Lokring is bottomed out. 17. Back off the screw and remove the installation tool. 18. Reconnect the heater hose to the heater line. 19. Fill the cooling system. 20. Reinstall the front inner fender well. 21. Reinstall the front passenger side tire. 22. Reinstall the air box. Complete Heater Line 1. Drain the cooling system. 2. Remove the air box. 3. Lift vehicle on hoist. 4. Remove passenger side tires. 5. Remove both front and rear inner fenders. 6. Disconnect the underhood heater lines using spring clamp release pliers. 7. Disconnect the rear heater lines at the rear heat core connections using spring clamp pliers. 8. Remove all body mount bolts on the passenger side and loosen the body mount bolts on the driver side. 9. Place a jack stand at the front and rear of the vehicle on the passenger side so that the stands will support the body. 10. Detach all underbody heater line brackets from the body that are accessible. 11. Lower the hoist until the body, that is being supported by the stands, is approximately 3-4 inches above the frame. This will allow access to the underbody assembly. 12. Remove all remaining heater line brackets that were not accessible before the body lift. 13. Remove the complete heater line assembly from the vehicle. 1/2" Rear Heater Tube Repair 1. Remove and isolate the battery negative cable from the battery. 2. Drain the cooling system. 3. Lift vehicle on hoist. 4. Pinch heater hoses in engine compartment. 5. Remove rear passenger tire. 6. Remove rear inner fender well. 7. Disconnect the heater hose from the rear heater core using constant tension clamp pliers. 8. Drain any remaining coolant from the underbody heater lines and rear heater core. 9. Mark cut location on tube on vehicle. 10. Cut tube on vehicle. 11. Size replacement tube, same size as tube removed from vehicle. 12. Scuff end of both tubes using pad provide in special tool kit. 13. Select proper Lokring for tube. 14. Put a drop of sealer from kit on the end of each tube, install Lokring and rotate to spread sealer evenly. 15. Put installation tool over the Lokring with tubes installed (tubes must be bottomed out in Lokring) 16. Select the proper jaws for the installation tool from the kit. 17. Compress Lokring using a wrench to draw the screw tight on the installation tool. Tighten the tool until the Lokring is bottomed out. 18. Connect the heater hose to the rear heater core using constant tension clamp pliers. 19. Install the rear inner fender well. 20. Install the passenger tire. 21. Remove the hose clamp from the heater hoses in the engine compartment. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 6036 22. Lower the vehicle on the hoist. 23. Refill the cooling system. 24. Connect the battery negative cable to the battery. INSTALLATION Complete Heater Line 1. Install the complete heater line assembly to the vehicle. 2. Install all heater line brackets that were not accessible before body lift. 3. Raise the hoist until the frame and body are lined up and the body mounts line up with the frame mounting pieces. 4. Install all remaining underbody heater line assembly brackets. 5. Install all body mount bolts on the passenger side and tighten both the passenger and driver side mount bolts. 6. Raise the lift until the jack stands are free, then remove the jack stands from under the vehicle. 7. Connect the underbody heater lines at the rear heater core. 8. Connect the front underhood heater lines using spring clamp pliers. 9. Install the front and rear inner fenders. 10. Install the passenger side tires. 11. Lower the vehicle on the lift. 12. Install the air box. 13. Refill the cooling system. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement Housing Assembly HVAC: Removal and Replacement Front HVAC Housing Removal and Installation REMOVAL HVAC Housing The heater-A/C housing assembly must be removed from the vehicle and disassembled for service access of the blower motor, blower motor wheel, heater core, evaporator coil, blend-air door, and each of the various mode control doors. WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE GENERAL INFORMATION BEFORE PERFORMING THE FOLLOWING OPERATION. - ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. The heater-A/C housing assembly must be removed from the vehicle and disassembled for service access of the blower motor; blower motor wheel, heater core, evaporator coil, blend-air door, and each of the various mode control doors. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel from the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly 3. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant Recovery, See: Refrigerant/Service and Repair/Refrigerant - Recovery 4. Remove the front expansion valve from the evaporator tube mounting flange. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Drain the engine cooling system. 6. Disconnect the heater hoses from the heater core tubes. Install plugs in, or tape over the opened heater core tubes. 7. Remove the four nuts from the heater-A/C housing mounting studs on the engine compartment side of the dash panel 8. Disengage the front floor panel transmission tunnel duct from the adapter on the heater-A/C housing. 9. Remove the two screws that retain the hanger strap and air inlet to the plenum. 10. Pull the heater-A/C housing rearward far enough for the mounting studs and the evaporator condensate drain tube to clear the dash panel holes. 11. Remove the heater-A/C housing from the vehicle. HVAC Housing Plenum Adapter WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the heater-A/C housing from the vehicle. 2. Slide the heater-A/C housing plenum adapter all the way to one side of the plenum opening. 3. Pull downwards sharply and firmly on the opposite side of the plenum adapter to disengage the snap feature from the plenum opening. 4. Remove the plenum adapter from the plenum panel. 5. When reinstalling the heater-A/C housing plenum adapter to the plenum panel opening, be certain that the snap features on each side of the adapter are fully engaged with the sides of the plenum panel opening. This must be a water tight connection to prevent leaks. INSTALLATION HVAC Housing 1. Position the heater-A/C housing to the dash panel. Be certain that the evaporator condensate drain tube and the housing mounting studs are inserted into their correct mounting holes. 2. Install the screw that secures the heater-A/C housing inlet to the plenum on the passenger compartment side of the dash panel. 3. Install and tighten the four nuts onto the heater-A/C housing mounting studs on the engine compartment side of the dash panel. Tighten the nuts to 7 Nm (60 in. lbs.). 4. Install the screw that secures the hanger strap to the plenum. 5. Engage the front floor panel transmission tunnel duct with the adapter on the heater-A/C housing. 6. Unplug or remove the tape from the heater core tubes. Connect the heater hoses to the heater core tubes and fill the engine cooling system. 7. Reinstall the front expansion valve to the evaporator tube mounting flange. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6041 8. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant - Evacuate, See: Refrigerant/Service and Repair/Refrigerant - Evacuate 9. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant Charge, See: Refrigerant/Service and Repair/Refrigerant - Charge 10. Reinstall the instrument panel in the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Pane Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly 11. Connect the battery negative cable. 12. Start the engine and check for proper operation of the heating and air conditioning systems. HVAC Housing Plenum Adapter 1. Install the heater-A/C housing plenum adapter to the plenum panel opening, be certain that the snap features on each side of the adapter are fully engaged with the sides of the plenum panel opening. This must be a water tight connection to prevent leaks. 2. Install the plenum adapter to the plenum panel. 3. Push upwards sharply and firmly on the opposite side of the plenum adapter to disengage the snap feature to the plenum opening. 4. Slide the heater-A/C housing plenum adapter onto the plenum opening. 5. Install the heater-A/C housing to the vehicle. Rear HVAC Housing Removal and Installation REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refrigerant Recovery, See: Refrigerant/Service and Repair/Refrigerant - Recovery 3. Lift vehicle on hoist. 4. Remove rear H-block bolt. Refer to Expansion Valve. See: Expansion Valve 5. Clamp off heater hoses. 6. Loosen hose clamps and remove hoses. Fig. 1 Rear HVAC Housing Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6042 7. Lower vehicle. 8. Remove right rear quarter trim panel. Refer to Body and Frame/Interior Trim/Trim Panel/Service and Repair. 9. Remove rear blower motor electrical connector. 10. Remove the rear mode door actuator electrical connector. 11. Remove the rear air mix actuator electrical connector. 12. Remove the floor vent duct outlets. Refer to Heating and Air Conditioning/Air Duct/Service and Repair. See: Air Duct/Service and Repair 13. Remove the rear overhead duct outlets. Refer to Heating and Air Conditioning/Air Duct/Service and Repair. See: Air Duct/Service and Repair 14. Remove the rear heater-A/C housing mounting bolts. 15. Remove the rear heater-A/C housing from the vehicle. INSTALLATION 1. Install the rear heater-A/C housing into the vehicle. 2. Install the rear heater-A/C housing bolts. 3. Install the rear overhead duct outlets. Refer to Heating and Air Conditioning/Air Duct/Service and Repair. See: Air Duct/Service and Repair 4. Install the floor vent duct outlets. Refer to Heating and Air Conditioning/Air Duct/Service and Repair. See: Air Duct/Service and Repair 5. Install the rear air mix actuator electrical connector. 6. Install the rear mode door actuator electrical connector. 7. Install the rear blower motor electrical connector. 8. Install the right rear quarter trim panel. Refer to Body and Frame/Interior Trim/Trim Panel/Service and Repair. 9. Lift vehicle on host. 10. Install hoses and tighten the hose clamps. 11. Remove clamps from heater hoses. 12. Install the rear H-block bolt. Refer to Expansion Valve. See: Expansion Valve/Service and Repair 13. Lower vehicle from host. 14. Evacuate A/C system. Refer to: Heating and Air Conditioning, Refrigerant, Servie and Repair, Refrigerant - Evacuate, See: Refrigerant/Service and Repair/Refrigerant - Evacuate 15. Recharge A/C system. Refer to: Heating and Air Conditioning, Refrigerant, Service and Repair, Refreigerant - Charge, See: Refrigerant/Service and Repair/Refrigerant - Charge 16. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6043 Housing Assembly HVAC: Overhaul DISASSEMBLY 1. With the heater-A/C housing on a work bench remove the three mode door actuator retainer screws. Refer to: Heating and Air Conditioning, Housing Assembly HVAC, Service and Repair, Rear, Rear HVAC Unit Removal and Installation, See: Removal and Replacement/Rear HVAC Housing Removal and Installation 2. Remove the mode door actuator from the heater-A/C housing. 3. Remove all screws and clips that hold the heater-A/C housing case together. 4. Separate the heater-A/C housing halves. ASSEMBLY 1. Place the heater-A/C housing halves together. Check all seals and if damaged replace as needed. 2. Install all screws and all clips that hold the heater-A/C housing together. 3. Install the mode door actuator to the heater-A/C housing. 4. Install the three mode door actuator retainer screws. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation Receiver Dryer: Description and Operation RECEIVER/DRIER - FORNT The filter-drier is mounted on the right front wheelhouse front extension in the engine compartment, in the liquid line between the condenser outlet and the evaporator inlet. Refrigerant enters the filter-drier as a high-pressure, high-temperature liquid. The filter-drier performs a filtering action to prevent foreign material in the refrigerant from contaminating the expansion valve. A desiccant bag is mounted inside the filter-drier canister to absorb any moisture which may have entered and become trapped within the refrigerant system. In addition, during periods of high demand air conditioner operation, the filter-drier acts as a reservoir to store surplus refrigerant. The filter-drier cannot be repaired. If the filter- drier is faulty or damaged, or if the refrigerant system has been contaminated or left open to the atmosphere for an indeterminable period, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation > Page 6047 Receiver Dryer: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 3. Remove the screws that secure the front and rear liquid line block fittings to the filter-drier inlet and outlet. 4. Disengage the block fittings from the filter- drier. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the screw that secures the filter-drier mounting bracket to the front fender wheelhouse front extension. 6. Remove the filter-drier from the engine compartment. INSTALLATION 1. Position the filter-drier and its bracket to the front fender wheelhouse front extension as a unit and loosely secure it with the mounting screw. 2. Remove the tape or plugs from the front liquid line block fitting and the filter-drier inlet. Install the front liquid line block fitting to the filter-drier inlet and secure the connection with a screw. Tighten the mounting screw to 13.5 Nm (120 in. lbs.). 3. Remove the tape or plugs from the rear liquid line block fitting and the filter-drier outlet. Install the rear liquid line block fitting to the filter-drier outlet and secure the connection with a screw. Tighten the mounting screw to 13.5 Nm (120 in. lbs.). 4. Tighten the filter-drier bracket mounting screw to 6.8 Nm (60 in. lbs.). 5. Connect the battery negative cable. 6. Evacuate the refrigerant system. 7. Charge the refrigerant system. NOTE: If the filter-drier is replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Information not supplied by the manufacturer Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 6052 Refrigerant: Fluid Type Specifications HydroFluoroCarbon (HFC), ....................................................................................................................................................... R-134a liquified freon gas Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 6053 Refrigerant: Service Precautions R-134a - R-12 Because R-134a refrigerant is a hydrofluorocarbon (HFC) which contains hydrogen atoms in place of chlorine atoms, it will not cause damage to the ozone layer. Ozone filters out harmful radiation from the sun. To assist in protecting the ozone layer, Chrysler Corporation recommends an R-134a refrigerant recycling device. The Clean Air Act Amendment of 1990 requires that Freon be recovered when accessing the air conditioning circuit and that technicians hold a refrigerant recovery and handling certification. The Ozone Layer A thin layer of ozone molecules, located 10 to 30 miles above the earth, form a protective cover by absorbing a portion of the ultraviolet (UV) radiation emitted from the Sun. Ozone Depletion Scientific research performed over the past 15 years links the release of chlorofluorocarbons (CFC)s, also know by the trade name Freon) into the atmosphere to ozone depletion. When CFCs are released into the atmosphere, they eventually reach the ozone layer located in the stratosphere where they react with and destroy ozone molecules. Harmful Effects Ozone depletion and the corresponding increase in UV radiation has been shown to lead to higher incidents of cancer as well as global warming. When viewed from a global perspective, ozone depletion holds an enormous potential for damage. Upper Level vs. Ground Level Ozone Confusion often arises when we hear about the necessity of the ozone layer and ground level ozone. The ozone layer existing high above the earth is beneficial but the same compound, when located at ground level, is harmful to humans, animals, crops and vegetation. Ground level ozone is a component of smog and forms when hydrocarbons (HC) react with nitrogen oxides (NOx) in the presence of sunlight and heat. Montreal Protocol In response to the growing body of evidence demonstrating the detrimental effects of (CFC)s, 24 countries and the European community met in Montreal, Canada, in 1987 to establish standards for the control of (CFC)s. Since that time, a total of 132 countries have become signatories to this agreement leading to an end of production of R12 in December, 1995, in all developed countries. As established by the Montreal Protocol, R12 production in developed countries has ceased. Clean Air Act The United States Congress, acting in response to the Montreal Protocol, banned production of (CFC)s by the year 2000. Congress also amended the Clean Air Act in an effort to control both the production and use of (CFC)s for refrigerant applications including mobile vehicle air conditioning systems. Technician Certification Organizations providing technician refrigerant recovery and recycling certification include: National Institute for Automotive Service Excellence (ASE) 13505 Dulles Technology Drive, Suite 2 Herndon, VA 22071-3421 Phone: (703) 713-3800 Fax: (703) 713-0727 http://www.asecert.org/ International Mobile Air Conditioning Association (IMACA) P.O. Box 9000 Fort Worth, TX 76147-2000 Phone: (817) 338-1100 Fax: (817) 338-1451 Mobile Air Conditioning Society (MACS) Worldwide P.O. Box 100 East Greenville, PA 18041 Phone: 215-679-2220 Fax: 215-541-4635 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 6054 http://www.macsw.org/ Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 6055 Refrigerant: Description and Operation REFRIGERANT The refrigerant used in this air conditioning system is a HydroFluoroCarbon (HFC), type R-134a. Unlike R-12, which is a ChloroFluoroCarbon (CFC), R-134a refrigerant does not contain ozone-depleting chlorine. R-134a refrigerant is a non-toxic, non-Hammable, clear, and colorless liquefied gas. Even though R-134a does not contain chlorine, it must be reclaimed and recycled just like CFC-type refrigerants. This is because R-134a is a greenhouse gas and can contribute to global warming. R-134a refrigerant is not compatible with R-12 refrigerant in an air conditioning system. Even a small amount of R-12 added to an R-134a refrigerant system will cause compressor failure, refrigerant oil sludge or poor air conditioning system performance. In addition, the PolyAlkylene Glycol (PAG) synthetic refrigerant oils used in an R-134a refrigerant system are not compatible with the mineral-based refrigerant oils used in an R-12 refrigerant system. R-134a refrigerant system service ports, service tool couplers and refrigerant dispensing bottles have all been designed with unique fittings to ensure that an R-134a system is not accidentally contaminated with the wrong refrigerant (R-12). There are also labels posted in the engine compartment of the vehicle and on the compressor identifying to service technicians that the air conditioning system is equipped with R-134a. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 6056 Refrigerant: Testing and Inspection If the air conditioning system does not cool properly, the A/C system performance should be tested. See A/C Performance for the procedures. If the A/C system refrigerant fill is found to be low or if the system is empty; a leak at a refrigerant line, connector fitting, component, or component seal is likely. An electronic leak detector designed for R-134a refrigerant, or a fluorescent R-134a leak detection dye and a black light are recommended for locating and confirming refrigerant system leaks. Refer to the operating instructions supplied by the equipment manufacturer for the proper care and use of this equipment. NOTE: A/C SYSTEM ALREADY CONTAINS A FACTORY INSTALLED FLUORESCENT DYE. An oily residue on or near refrigerant system lines, connector fittings, components, or component seals can indicate the general location of a possible refrigerant leak. However, the exact leak location should be confirmed with an electronic leak detector prior to component repair or replacement. To detect a leak in the refrigerant system with an electronic leak detector, perform one of the following procedures: SYSTEM EMPTY 1. Evacuate the refrigerant system. 2. Connect and dispense 0.283 kilograms (0.625 pounds or 10 ounces) of R-134a refrigerant into the evacuated refrigerant system. 3. Position the vehicle in a wind-free work area. This will aid in detecting small leaks. 4. With the engine not running, use an electronic R-134a leak detector and search for leaks. Because R-134a refrigerant is heavier than air, the leak detector probe should be moved slowly along the bottom side of all refrigerant lines, connector fittings and components. 5. To inspect the front evaporator coil for leaks, insert the electronic leak detector probe into the center instrument panel outlet and the floor duct outlet. Set the front blower motor switch to the lowest speed position, and the mode control switch to the recirculation mode (Max-A/C). 6. To inspect for leaks in the rear evaporator, put the rear system in the floor mode and place the probe in the rear unit floor outlet. SYSTEM LOW 1. Position the vehicle in a wind-free work area. This will aid in detecting small leaks. 2. Bring the refrigerant system up to operating temperature and pressure. This is done by allowing the engine to run with the air conditioning system turned on for five minutes. 3. With the engine not running, use an electronic R-134a leak detector and search for leaks. Because R-134a refrigerant is heavier than air, the leak detector probe should be moved slowly along the bottom side of all refrigerant lines, connector fittings and components. 4. To inspect the evaporator coil for leaks, insert the electronic leak detector probe into the center instrument panel outlet and the floor duct outlet. Set the front blower motor switch to the lowest speed position, and the mode control switch to the recirculation mode (Max-A/C). 5. To detect a leak in the rear evaporator, put the rear system in the floor mode and place the probe in the rear unit floor outlet. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant - Recovery Refrigerant: Service and Repair Refrigerant - Recovery A R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J22 10 must be used to recover the refrigerant from an R-134a refrigerant system. Refer to the operating instructions supplied by the equipment manufacturer for the proper care and use of this equipment. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant - Recovery > Page 6059 Refrigerant: Service and Repair Refrigerant - Evacuate If the refrigerant system has been open to the atmosphere, it must be evacuated before the system can be charged. If moisture and air enters the system and becomes mixed with the refrigerant, the compressor head pressure will rise above acceptable operating levels. This will reduce the performance of the air conditioner and damage the compressor. Evacuating the refrigerant system will remove the air and boil the moisture out of the system at near room temperature. To evacuate the refrigerant system, use the following procedure: 1. Connect a R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 and a manifold gauge set to the refrigerant system of the vehicle. 2. Open the low and high side valves and start the charging station vacuum pump. When the suction gauge reads 88 kPa (26 in. Hg.) vacuum or greater, close all of the valves and turn OFF the vacuum pump. a. If the refrigerant system fails to reach the specified vacuum, the system has a leak that must be corrected. See Refrigerant System Leaks in the Diagnosis and Testing for the procedures. b. If the refrigerant system maintains the specified vacuum for five minutes, restart the vacuum pump, open the suction and discharge valves and evacuate the system for an additional ten minutes. 3. Close all of the valves, and turn OFF the charging station vacuum pump. 4. The refrigerant system is now ready to be charged with R-134a refrigerant. See Refrigerant System Charge in the Service Procedures. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant - Recovery > Page 6060 Refrigerant: Service and Repair Refrigerant - Charge The R-134a refrigerant system charge capacity for this vehicle can be found on the underhood A/C specification sheet. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Total System Front .................................................................................................................................................... ...................................................... 210 ml (7.1 oz.) Front & Rear ....................................................... ..................................................................................................................................... 300 ml (10.1 oz.) Filter-Drier ............................................................................................................................................ ............................................................. 30 ml (1 oz.) Condenser ........................................................................................................................................... ................................................................ 30 ml (1 oz.) Evaporator Front .................................................................................................................................................... ........................................................... 60 ml (2 oz.) Rear .................................................................... ............................................................................................................................................ 30 ml (1 oz.) Compressor ......................................................................................................................................... ...................................................................... See Note Note: When replacing the A/C compressor, drain and measure the amount of oil from the old compressor. Add the equivalent amount of fresh oil to the new compressor. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 6065 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil Type ............................................................................................................................ ............................................................... SP-15 PAG Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 6066 Refrigerant Oil: Service and Repair REFRIGERANT OIL - FRONT The refrigerant oil used in R-134a refrigerant systems is a synthetic-based, PolyAlkylene Glycol (PAG), wax-free lubricant. Mineral-based R-12 refrigerant oils are not compatible with PAG Oils and should never be introduced to an R-134a refrigerant system. There are different PAG oils available, and each contains a different additive package. The SD7H15 compressor used in this vehicle is designed to use an SP-20 PAG refrigerant oil. Use only refrigerant oil of this same type to service the refrigerant system. After performing any refrigerant recovery or recycling operation, always replenish the refrigerant system with the same amount of the recommended refrigerant oil as was removed. Too little refrigerant oil can cause compressor damage, and too much can reduce air conditioning system performance. PAG refrigerant oil is much more hygroscopic than mineral oil, and will absorb any moisture it comes into contact with, even moisture in the air. The PAG oil container should always be kept tightly capped until it is ready to be used. After use, recap the oil container immediately to prevent moisture contamination. REFRIGERANT OIL LEVEL - FRONT When an air conditioning system is assembled at the factory, all components except the compressor are refrigerant oil free. After the refrigerant system has been charged and operated, the refrigerant oil in the compressor is dispersed throughout the refrigerant system. The evaporator, filter-drier, condenser, and compressor will each retain a significant amount of the needed refrigerant oil. It is important to have the correct amount of oil in the refrigerant system. This ensures proper lubrication of the compressor. Too little oil will result in damage to the compressor. Too much oil will reduce the cooling capacity of the air conditioning system. It will not be necessary to check the oil level in the compressor or to add oil, unless there has been an oil loss. An oil loss may occur due to a rupture or leak from a refrigerant line, a connector fitting, a component, or a component seal. If a leak occurs, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system after the repair has been made. Refrigerant oil loss will be evident at the leak point by the presence of a wet, shiny surface around the leak. Refrigerant Oil Capacities Chart Refrigerant oil must be added when a filter-drier, evaporator coil, or condenser are replaced. See the Refrigerant Oil Capacities chart. When a compressor is replaced, the refrigerant oil must be drained from the old compressor and measured. Drain all of the refrigerant oil from the new compressor, then fill the new compressor with the same amount of refrigerant oil that was drained out of the old compressor. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Diagrams High Pressure Sensor / Switch: Diagrams A/C Low Pressure Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Specifications Low Pressure Sensor / Switch: Specifications Low Pressure Cycling Switch: Hand Tighten Only ........................................................................................................................................ (n/a) (n/a) (n/a) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 6074 Low Pressure Sensor / Switch: Diagrams A/C Low Pressure Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 6075 Low Pressure Sensor / Switch: Description and Operation LOSS OF CHARGE SWITCH - FRONT This vehicle is equipped with a Loss of Charge Switch. This switch is screwed onto a fitting on the suction jumper line between the evaporator and the low side refrigerant system service port. The switch is used to measure if refrigerant system pressure goes too low. It is not responsible for cycling the A/C compressor clutch. The loss of charge switch is connected in series electrically with the Heater-A/C controls between ground and the Powertrain Control Module (PCM). The switch contacts open and close causing the PCM to turn the compressor clutch ON and OFF. This prevents compressor operation when the system charge is low and prevents damage to the compressor. The switch opens with a pressure of 7 to 13 psi and closes when the pressure rises to 15 to 25 psi. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 6076 Low Pressure Sensor / Switch: Testing and Inspection Before performing diagnosis of the loss of charge switch, be certain that the switch is properly installed on the suction jumper line fitting. If the switch is too loose it may not open the Schrader-type valve in the accumulator fitting, which will prevent the switch from correctly monitoring the refrigerant system pressure. Remember that lower ambient temperatures during cold weather will open the switch contacts and prevent compressor operation due to the pressure/temperature relationship of the refrigerant. Also verify that the refrigerant system has the correct refrigerant charge. 1. Disconnect and isolate the battery negative cable. 2. Unplug the a/c loss of charge switch wire harness connector from the switch on the refrigerant system fitting. 3. Install a jumper wire between the two cavities of the loss of charge switch harness connector. 4. Connect a manifold gauge set to the refrigerant system service ports. 5. Connect the battery negative cable. 6. Place the heater-A/C mode control switch knob in any A/C position and start the engine. 7. Check for continuity between the two terminals of the loss of charge switch. There should be continuity with a suction pressure reading of 7 to 13 psi. If OK, test and repair the A/C switch sense circuit as required. If not OK, replace the faulty switch. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 6077 Low Pressure Sensor / Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the A/C loss of charge switch switch, which is mounted to a fitting on the discharge line between the compressor and the condenser inlet. 3. Unscrew the loss of charge switch from the suction jumper line fitting. 4. Remove the loss of charge switch from the vehicle. 5. Remove the O-ring seal from the discharge line fitting and discard. INSTALLATION 1. Lubricate a new O-ring seal with clean refrigerant oil and install it on the suction jumper line fitting. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 2. Install and tighten the loss of charge switch on the suction jumper line fitting. 3. Plug the wire harness connector into the loss of charge switch. 4. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations Power Distribution Center Blower Motor Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 6082 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 6083 Blower Motor Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 6084 Rear Blower Motor Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Power Distribution Center A/C Clutch Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6088 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6089 Compressor Clutch Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6090 A/C Compressor Clutch Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6091 Compressor Clutch Relay: Description and Operation COMPRESSOR CLUTCH RELAY - FRONT The compressor clutch relay is an International Standards Organization (ISO) micro-relay. The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (footprint) is different, the current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The compressor clutch relay is an electromechanical device that switches battery current to the compressor clutch coil when the Powertrain Control Module (PCM) grounds the coil side of the relay. The PCM responds to inputs from the heater-A/C mode control switch, the evaporator temperature sensor, the loss of charge switch, and the pressure transducer. See Compressor Clutch Relay in the Diagnosis and Testing for more information. The compressor clutch relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identification and location. The compressor clutch relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6092 Compressor Clutch Relay: Testing and Inspection Fig.12 Compressor Clutch Relay RELAY TEST The compressor clutch relay is located in the Power Distribution Center (PDC). Refer to the PDC label for relay identification and location. Remove the relay from the PDC to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see the Relay Circuit Test below. If not OK, replace the faulty relay. RELAY CIRCUIT TEST 1. The relay common feed terminal cavity (30) is connected to fused battery feed. There should be battery voltage at the cavity for relay terminal 30 at all times. If OK, go to Step 2. If not OK, repair the open circuit to the fuse in the PDC as required. 2. The relay normally closed terminal (87A) is not used in this application. Go to Step 3. 3. The relay normally open terminal cavity (87) is connected to the compressor clutch coil. There should be continuity between this cavity and the A/C compressor clutch relay output circuit cavity of the compressor clutch coil wire harness connector. If OK, go to Step 4. If not OK, repair the open circuit as required. 4. The relay coil battery terminal (86) is connected to the fused ignition switch output (run/start) circuit. There should be battery voltage at the cavity for relay terminal 86 with the ignition switch in the ON position. If OK, go to Step 5. If not OK, repair the open circuit to the fuse in the junction block as required. 5. The coil ground terminal cavity (85) is switched to ground through the Powertrain Control Module (PCM). There should be continuity between this cavity and the A/C compressor clutch relay control circuit cavity of the PCM wire harness connector C (gray) at all times. If not OK, repair the open circuit as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6093 Compressor Clutch Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Fig. 13 Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for compressor clutch relay identification and location. 4. Unplug the compressor clutch relay from the PDC. INSTALLATION 1. Install the compressor clutch relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 2. Install the PDC cover. 3. Connect the battery negative cable. 4. Test the relay operation. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams Ambient Temperature Sensor / Switch HVAC: Diagrams Ambient Temperature Sensor Ambient Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Page 6098 Ambient Temperature Sensor / Switch HVAC: Description and Operation AMBIENT TEMP SENSOR - FRONT Ambient air temperature is monitored by the compass mini-trip computer module through the ambient temperature sensor. The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the right side of the radiator yoke, behind the radiator grille and in front of the engine compartment. For complete circuit diagrams, refer to Overhead Console in the Contents of Wiring Diagrams. The ambient temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent to it by the compass mini-trip computer module. The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the compass mini-trip computer module. Based upon the resistance in the sensor, the compass mini-trip computer module senses a specific voltage on the temperature sensor signal circuit, which it is programmed to correspond to a specific temperature. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Page 6099 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection The thermometer function is supported by the ambient temperature sensor, a wiring circuit, and a portion of the compass mini-trip computer module. If any portion of the ambient temperature sensor circuit fails, the compass/thermometer display function will self-diagnose the circuit. An "SC" (short circuit) will appear in the display in place of the temperature, when the sensor is exposed to temperatures above 110 °C (230 °F), or if the sensor circuit is shorted. An "OC", (open circuit) will appear in the display in place of the temperature, when the sensor is exposed to temperatures below -50 °C (-58 ° F), or if the sensor circuit is open. The ambient temperature sensor circuit can also be diagnosed using the following Sensor Test, and Sensor Circuit Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, refer to Compass Mini-Trip Computer in the Diagnosis and Testing. For complete circuit diagrams, refer to Overhead Console in the Contents of Wiring Diagrams. Sensor Test 1. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor wire harness connector. 2. Measure the resistance of the ambient temperature sensor. At -40 °C (-40 °F), the sensor resistance is 336 kilo ohms. At -55 °C (131 °F), the sensor resistance is 2.488 kilo ohms. The sensor resistance should read between these two values. If OK, refer to Sensor Circuit Test in the Diagnosis and Testing. If not OK, replace the faulty ambient temperature sensor. Sensor Circuit Test 1. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor wire harness connector and the overhead console wire harness connector. 2. Connect a jumper wire between the two terminals in the body half of the ambient temperature sensor wire harness connector. 3. Check for continuity between the sensor return circuit and the ambient temperature sensor signal circuit cavities of the roof wire harness overhead console connector. There should be continuity. If OK, go to Step 4. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 4. Remove the jumper wire from the body half of the ambient temperature sensor wire harness connector. Check for continuity between the sensor return circuit cavity of the roof wire harness overhead console connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted sensor return circuit as required. 5. Check for continuity between the ambient temperature sensor signal circuit cavity of the roof wire harness overhead console connector and a good ground. There should be no continuity. If OK, refer to Compass Mini-Trip Computer in the Diagnosis and Testing. If not OK, repair the shorted ambient temperature sensor signal circuit as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Page 6100 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Fig. 17 Ambient Temperature Sensor Remove/Install 2. Locate the ambient temperature sensor, on the right side of the radiator yoke behind the grille. 3. Disconnect the wire harness connector from the ambient temperature sensor connector receptacle. 4. Remove the one screw that secures the ambient temperature sensor bracket to the radiator yoke. 5. Remove the ambient temperature sensor from the radiator yoke. INSTALLATION 1. Position the ambient temperature sensor onto the radiator yoke. 2. Install and tighten the one screw that secures the ambient temperature sensor bracket to the radiator yoke. Tighten the screw to 5.6 Nm (50 in. lbs.) . 3. Reconnect the wire harness connector to the ambient temperature sensor connector receptacle. 4. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation Blower Motor Switch: Description and Operation BLOWER MOTOR SWITCH - FRONT The heater-A/C blower motor is controlled by a four position rotary-type blower motor switch, mounted in the heater-A/C control panel. The switch allows the selection of one of four blower motor speeds, but can only be turned OFF by selecting the OFF position with the heater-A/C mode control switch knob. The blower motor switch directs the blower motor ground path through the mode control switch to the blower motor resistor, or directly to ground through the high speed blower motor relay, as required to achieve the selected blower motor speed. The blower motor switch cannot be repaired and, if faulty or damaged, the entire heater-A/C control unit must be replaced. The blower motor switch knob is serviced separately. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation > Page 6104 Blower Motor Switch: Testing and Inspection For circuit descriptions, diagrams and electrical test procedures for blower switch. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation > Page 6105 Blower Motor Switch: Service and Repair REMOVAL The rear blower motor switch is integrated into the rear control and is used only on models with the optional rear heater-A/C unit. 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick or another suitable wide flat-bladed tool, gently pry above the two indentations at the outer perimeter of the rear control to release it from the headliner. 3. Pull the rear blower motor switch away from the headliner far enough to access and unplug the wire harness connector from the back of the switch. 4. Remove the rear blower motor switch from the headliner. INSTALLATION The rear blower motor switch is used only on models with the optional rear heating-A/C unit. 1. Plug the wire harness connector into the back of the rear blower motor switch. 2. Tuck the wire harness back through the rear blower motor switch mounting hole in the headliner. 3. Gently press the rear blower motor switch into the mounting hole in the headliner until it snaps into place. 4. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams Evaporator Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Diagrams High Pressure Sensor / Switch: Diagrams A/C Low Pressure Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Specifications Low Pressure Sensor / Switch: Specifications Low Pressure Cycling Switch: Hand Tighten Only ........................................................................................................................................ (n/a) (n/a) (n/a) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 6116 Low Pressure Sensor / Switch: Diagrams A/C Low Pressure Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 6117 Low Pressure Sensor / Switch: Description and Operation LOSS OF CHARGE SWITCH - FRONT This vehicle is equipped with a Loss of Charge Switch. This switch is screwed onto a fitting on the suction jumper line between the evaporator and the low side refrigerant system service port. The switch is used to measure if refrigerant system pressure goes too low. It is not responsible for cycling the A/C compressor clutch. The loss of charge switch is connected in series electrically with the Heater-A/C controls between ground and the Powertrain Control Module (PCM). The switch contacts open and close causing the PCM to turn the compressor clutch ON and OFF. This prevents compressor operation when the system charge is low and prevents damage to the compressor. The switch opens with a pressure of 7 to 13 psi and closes when the pressure rises to 15 to 25 psi. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 6118 Low Pressure Sensor / Switch: Testing and Inspection Before performing diagnosis of the loss of charge switch, be certain that the switch is properly installed on the suction jumper line fitting. If the switch is too loose it may not open the Schrader-type valve in the accumulator fitting, which will prevent the switch from correctly monitoring the refrigerant system pressure. Remember that lower ambient temperatures during cold weather will open the switch contacts and prevent compressor operation due to the pressure/temperature relationship of the refrigerant. Also verify that the refrigerant system has the correct refrigerant charge. 1. Disconnect and isolate the battery negative cable. 2. Unplug the a/c loss of charge switch wire harness connector from the switch on the refrigerant system fitting. 3. Install a jumper wire between the two cavities of the loss of charge switch harness connector. 4. Connect a manifold gauge set to the refrigerant system service ports. 5. Connect the battery negative cable. 6. Place the heater-A/C mode control switch knob in any A/C position and start the engine. 7. Check for continuity between the two terminals of the loss of charge switch. There should be continuity with a suction pressure reading of 7 to 13 psi. If OK, test and repair the A/C switch sense circuit as required. If not OK, replace the faulty switch. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 6119 Low Pressure Sensor / Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the A/C loss of charge switch switch, which is mounted to a fitting on the discharge line between the compressor and the condenser inlet. 3. Unscrew the loss of charge switch from the suction jumper line fitting. 4. Remove the loss of charge switch from the vehicle. 5. Remove the O-ring seal from the discharge line fitting and discard. INSTALLATION 1. Lubricate a new O-ring seal with clean refrigerant oil and install it on the suction jumper line fitting. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 2. Install and tighten the loss of charge switch on the suction jumper line fitting. 3. Plug the wire harness connector into the loss of charge switch. 4. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations Service Port HVAC: Locations The high pressure service port is located on the liquid line between the condenser and the evaporator, near the front of the engine compartment. The low pressure service port is on the suction line between the compressor and the evaporator for the this engine. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page 6123 Service Port HVAC: Description and Operation The two refrigerant system service ports are used to charge, recover/recycle, evacuate, and test the air conditioning refrigerant system. Unique service port coupler sizes are used on the R-134a system, to ensure that the refrigerant system is not accidentally contaminated by the use of the wrong refrigerant (R-12), or refrigerant system service equipment. The high pressure service port is located on the liquid line between the condenser and the evaporator, near the front of the engine compartment. The low pressure service port is on the suction line between the compressor and the evaporator for the this engine. Each of the service ports has a threaded plastic protective cap installed over it from the factory. After servicing the refrigerant system, always reinstall both of the service port caps. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System Repairs and Inspections Required After a Collision: Service and Repair Air Bag System STANDARD PROCEDURE - SERVICE AFTER A PASSIVE RESTRAINT DEPLOYMENT Any vehicle which is to be returned to use following a passive restraint deployment, must have both airbags, both seat belt tensioners, the driver airbag trim cover, the horn switch, the clockspring, and the steering column assembly replaced. These components are not intended for reuse and will be damaged or weakened as a result of an airbag deployment, which may or may not be obvious during a visual inspection. Other vehicle components should be closely inspected, but are to be replaced only as required by the extent of the visible damage incurred. CLEAN-UP PROCEDURE Following an airbag deployment, the vehicle interior will contain a powdery residue. This residue consists primarily of harmless particulate by-products of the small pyrotechnic charge used to initiate the propellant used to deploy the airbags. However, this residue may also contain traces of sodium hydroxide powder, a chemical by-product of the propellant material that is used to generate the nitrogen gas that inflates the airbag. Since sodium hydroxide powder can irritate the skin, eyes, nose, or throat, be sure to wear safety glasses, rubber gloves, and a long-sleeved shirt during cleanup (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. CAUTION: All damaged, faulty, or non-deployed supplemental restraints which are replaced on vehicles are to be handled and disposed of properly. If an airbag or seat belt tensioner unit is faulty or damaged and non-deployed, refer to the Hazardous Substance Control System for proper disposal. Be certain to dispose of all non-deployed and deployed supplemental restraints in a manner consistent with state, provincial, local and federal regulations. Begin the cleanup by removing both airbags and both seat belt tensioners from the vehicle. Next, 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 a non-cleaned area. Be certain to vacuum the heater and air conditioning outlets as well (Vacuum Heater and A/C Outlets - Typical). Run the heater and air conditioner 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System > Page 6129 Repairs and Inspections Required After a Collision: Service and Repair Seat Belt System REPAIRS AND INSPECTIONS REQUIRED AFTER A COLLISION RESTRAINT SYSTEM After a impact where an airbag has been deployed due to a collision, the following MUST be replaced: 1. Front Seat Belts and Retractors (driver and passenger) with integral Tensioners. 2. After an impact that deploys the airbag, the seat belt tensioner assembly must be replaced. WARNING: WHEN THE FRONT AIRBAG IS DEPLOYED, THE TENSIONER WILL HAVE DEPLOYED ALSO AND MUST BE REPLACED. 3. Do not reuse the bolts attaching the seat belt retractor to the seat frame. Failure to follow proper installation procedure may result in the seat track latch pins not being synchronized. 4. Inspect the condition of the shoulder/lap belt. replace the retractor if the belt is cut, frayed, torn, or damaged in any way. The rear seat back retaining nut also serves as the center seat belt anchor. Be certain to torque this nut. 5. All seat belts should be closely inspected for cuts, tears, fraying, or damage in any way following any frontal impact or airbag deployment. The seat belts are to be replaced when visible damage is incurred. Inspect the Lower Anchors and Tether for Children (LATCH) child restraint anchors for damage after an impact event and replace as needed. 6. During, and following, any child restraint anchor service, due to impact event or vehicle repair, carefully inspect all mounting hardware, tether straps and anchors for proper installation, operation, or damage. if a child restraint anchor is found damaged in any way, the anchor must be replaced with the seat assembly. failure to do so could result in occupant personal injury or death. NOTE: Never attempt to repair a seat belt component. always replace damaged or faulty seat belt components with the correct, new and unused replacement parts. VEHICLES EQUIPPED WITH THE OCCUPANT CLASSIFICATION SYSTEM (OCS) If any of the Occupant Classification System (OCS) components of the passenger side front seat cushion require replacement, they are serviced only as a factory-calibrated, assembled, and tamper-evident service replacement package. This package includes the assembled frame, springs, pad, seat weight bladder and pressure sensor, foam, wiring and a calibrated OCM. When installing this package, always replace all of the existing components with the new components as a unit. Do not attempt to separate or disconnect any of the new OCS components contained in the service replacement package from each other, and do not attempt to reuse any of the replaced components in this or any other vehicle. CAUTION: Never replace both the Airbag Control Module (ACM) and the Occupant Classification Module (OCM) at the same time. If both require replacement, replace one. Then perform the supplemental restraint verification test before replacing the other. Both the ACM and the OCM store OCS calibration data, which they transfer to one another when one of them is replaced. If both are replaced at the same time, an irreversible fault will be set in both modules. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 6134 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Driver Airbag - Trim Cover Service Air Bag: Technical Service Bulletins Driver Airbag - Trim Cover Service NUMBER: 19-009-01 GROUP: Steering DATE: Oct. 26, 2001 SUBJECT: Driver Airbag Trim Cover Service MODELS: 1999 - 2002 (AB) Ram Van 1997 - 2002 (AN) Dakota 1997 - 2002 (BE/BR) Ram Truck 1998 - 2002 (DN) Durango 2002 (DR) Ram Truck 2001 - 2002 (JR) Sebring/Sebring Convertible/Stratus 1998 - 2002 (LH) LHS/300M/Concorde/Intrepid 2001 (PT) Chrysler PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Voyager/Caravan 2000 - 2001 (R1) Dakota (International Markets) 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1997 - 2002 (XJ) Cherokee 1997 - 1998 (ZG) Grand Cherokee (International Markets) 1997 - 1998 (ZJ) Grand Cherokee DISCUSSION: Driver airbag trim covers/horn switches for the above vehicles are serviceable and as such, when applicable, must be used instead of replacing the airbag module assembly. Airbag module assemblies returned for trim cover and serviceable horn switch issues, are subject to charge back. In most cases, the service manuals show driver airbag replacement procedures in the Restraints section of Group 8. Several MOPAR driver airbag cover packages include instruction sheets. Because of the long list of part numbers involved they are not listed here, please consult the MOPAR parts catalog for the correct part number(s). WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Driver Airbag - Trim Cover Service > Page 6139 WARNING: THE HORN SWITCH IS INTEGRAL TO THE DRIVER AIRBAG UNIT. ONLY DAIMLERCHRYSLER-TRAINED AND AUTHORIZED DEALER SERVICE TECHNICIANS SHOULD PERFORM SERVICE OF THIS UNIT. FAILURE TO TAKE THE PROPER PRECAUTIONS OR TO FOLLOW THE PROPER PROCEDURES COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. WARNING: USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE DRIVER AIRBAG, OR BECOMING ENTRAPPED BETWEEN THE DRIVER AIRBAG CUSHION AND THE DRIVER AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. WARNING: THE DRIVER AIRBAG TRIM COVER MUST NEVER BE PAINTED. REPLACEMENT TRIM COVERS ARE SERVICED IN THE ORIGINAL COLORS. PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE TRIM COVER RESPONDS TO AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. The following can be used for all airbag trim cover replacements: TIME ALLOWANCE: FAILURE CODE: POLICY: Reimbursable within the provisions of the warranty. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Driver Airbag - Trim Cover Service > Page 6140 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Driver Airbag - Trim Cover Service > Page 6141 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 6142 Air Bag: Locations The driver airbag is located in the center of the steering wheel, where it is secured with two screws to the steering wheel armature. The passenger airbag is located in the instrument panel in front of the front seat passenger seating position, where it is secured to the instrument panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 6143 Air Bag: Diagrams Driver Airbag Passenger Airbag Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 6144 Air Bag: Service Precautions WARNING: - DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - WHEN REMOVING A DEPLOYED AIRBAG, RUBBER GLOVES, EYE PROTECTION, AND A LONG-SLEEVED SHIRT SHOULD BE WORN. THERE MAY BE DEPOSITS ON THE AIRBAG CUSHION AND OTHER INTERIOR SURFACES. IN LARGE DOSES, THESE DEPOSITS MAY CAUSE IRRITATION TO THE SKIN AND EYES. - USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE DRIVER AIRBAG, OR BECOMING ENTRAPPED BETWEEN THE DRIVER AIRBAG CUSHION AND THE DRIVER AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. - THE DRIVER AIRBAG TRIM COVER MUST NEVER BE PAINTED. REPLACEMENT TRIM COVERS ARE SERVICED IN THE ORIGINAL COLORS. PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE TRIM COVER RESPONDS TO AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. - THE HORN SWITCH IS INTEGRAL TO THE DRIVER AIRBAG UNIT. SERVICE OF THIS UNIT SHOULD BE PERFORMED ONLY BY DAIMLERCHRYSLER-TRAINED AND AUTHORIZED DEALER SERVICE TECHNICIANS. FAILURE TO TAKE THE PROPER PRECAUTIONS OR TO FOLLOW THE PROPER PROCEDURES COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. - USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE PASSENGER AIRBAG, OR BECOMING ENTRAPPED BETWEEN THE PASSENGER AIRBAG CUSHION AND THE PASSENGER AIRBAG DOOR. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. - THE PASSENGER AIRBAG DOOR MUST NEVER BE PAINTED. REPLACEMENT PASSENGER AIRBAG DOORS ARE SERVICED IN THE ORIGINAL COLORS. PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE AIRBAG DOOR RESPONDS TO AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 6145 Air Bag: Description and Operation Fig. 10 Driver Airbag Fig.11 Horn Switch DRIVER AIRBAG The driver airbag protective trim cover is the most visible part of the driver airbag. The airbag used in this model is a Next Generation-type that Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 6146 complies with revised federal airbag standards to deploy with less force than those used in some prior models. The driver airbag is located in the center of the steering wheel, where it is secured with two screws to the steering wheel armature. Concealed beneath the driver airbag trim cover are the horn switch, the folded airbag cushion, the airbag retainer or housing, the airbag inflator, and the retainers that secure the inflator to the airbag housing. The resistive membrane-type horn switch is secured within a plastic tray that is inserted in a pocket or pouch sewn onto the airbag cushion retainer strap, between the trim cover and the folded airbag cushion. The airbag inflator is a conventional non-azide, pyrotechnic-type unit with four studs and it is secured to the stamped metal airbag housing with four nuts. The trim cover has an airbag receptacle molded into the back side of it. The four vertical walls of this receptacle have a total of twelve small windows with blocking tabs that are engaged by twelve hook formations around the perimeter of the airbag housing. Each hook is inserted through one of the windows, the integral blocking tab in each window keeps each hook properly engaged with the trim cover, locking the cover securely into place. One horn switch pigtail wire has an eyelet terminal connector that is captured beneath a nut and washer on the upper right inflator mounting stud. The other horn switch pigtail wire is routed between the upper left inflator mounting stud and the inflator, where it is captured by a small plastic retainer that is pushed onto the stud. The driver airbag cannot be repaired, and must be replaced if deployed or in any way damaged. The driver airbag trim cover and the horn switch with tray are available, and may be disassembled from the driver airbag for service replacement. The driver airbag is deployed by an electrical signal generated by the Airbag Control Module (ACM) through the driver airbag line 1 and line 2 (or squib) circuits. When the ACM sends the proper electrical signal to the airbag inflator, the electrical energy generates enough heat to initiate a small pyrotechnic charge which, in turn, ignites chemical pellets within the inflator. Once ignited, these chemical pellets burn rapidly and produce a large quantity of nitrogen gas. The inflator is sealed to the back of the airbag housing and a diffuser in the inflator directs all of the nitrogen gas into the airbag cushion, causing the cushion to inflate. As the cushion inflates, the driver airbag trim cover will split at predetermined breakout lines, then fold back out of the way along with the horn switch and tray unit. Following an airbag deployment, the airbag cushion quickly deflates by venting the nitrogen gas towards the instrument panel through the porous fabric material used on the steering wheel side of the airbag cushion. Some of the chemicals used to create the nitrogen gas may be considered hazardous in their solid state, before they are burned, but they are securely sealed within the airbag inflator. However, the nitrogen gas that is produced when the chemicals are burned is harmless. A small amount of residue from the burned chemicals may cause some temporary discomfort if it contacts the skin, eyes, or breathing passages. If skin or eye irritation is noticed, rinse the affected area with plenty of cool, clean water. If breathing passages are irritated, move to another area where there is plenty of clean, fresh air to breath. If the irritation is not alleviated by these actions, contact a physician. PASSENGER AIRBAG The rearward facing surface of the passenger airbag door above the glove box is the most visible part of the passenger airbag. The airbag used in this model is a Next Generation-type that complies with revised federal airbag standards to deploy with less force than those used in some prior models. The passenger airbag is located in the instrument panel in front of the front seat passenger seating position, where it is secured to the instrument panel. Concealed beneath the passenger airbag door are the folded airbag cushion, the airbag retainer or housing, and the airbag inflator. The airbag inflator is a hybrid-type unit that is secured to and sealed within the airbag housing along with the folded airbag cushion. The airbag housing is constructed of a long U-shaped aluminum extrusion with two stamped steel end plates. 'Two tabs that extend from the bottom of the extrusion serve as the rear mounting brackets, while an angled foot on the bottom of each end plate serve as the front mounting brackets. The front brackets are secured with screws to the instrument panel armature above the glove box, while the rear brackets are secured with screws to the upper glove box opening reinforcement. A yellow connector on the end of a short, two-wire pigtail harness connects the passenger airbag inflator to the vehicle electrical system. The molded plastic passenger airbag door has a predetermined horizontal breakout line near its center which is concealed beneath its decorative outer surface. Return flanges near the top and bottom of the airbag door feature windows that are engaged on hook formations at the top and bottom of the airbag housing. Three tabs extend downward from the lower return flange and are secured with the same screws that secure the glove box module to the upper glove box opening reinforcement. Five molded snap features along the top of the airbag door above the upper return flange snap into receptacles located in the instrument panel base trim just below the instrument panel top cover. Following a passenger airbag deployment, the passenger airbag and airbag door unit must be replaced. The passenger airbag cannot be repaired, and must be replaced if faulty or in any way damaged. The passenger airbag door is serviced only as a unit with the passenger airbag. The passenger airbag is deployed by an electrical signal generated by the Airbag Control Module (ACM) through the passenger airbag line 1 and line 2 (or squib) circuits. The hybrid-type inflator assembly includes a small canister of highly compressed argon gas. When the ACM sends the proper electrical signal to the airbag inflator, the electrical energy generates enough heat to ignite chemical pellets within the inflator. Once ignited, these chemical pellets burn rapidly and produce the pressure necessary to rupture a containment disk in the argon gas canister. The inflator and argon gas canister are sealed to the airbag cushion so that all of the released argon gas is directed into the airbag cushion, causing the cushion to inflate. As the cushion inflates, the passenger airbag door will split at the breakout line and the two halves of the door will pivot out of the way. Following an airbag deployment, the airbag cushion quickly deflates by venting the argon gas through vents on the instrument panel side of the airbag cushion. Some of the chemicals used to create the pressure to burst the argon gas containment disk are considered hazardous in their solid state, before they are burned, but they are securely sealed within the airbag inflator. However, the gas that is produced when the chemicals are burned is harmless. A small amount of residue from the burned chemicals may cause some temporary discomfort if it contacts the skin, eyes, or breathing passages. If skin or eye irritation is noticed, rinse the affected area with plenty of cool, clean water. If breathing passages are irritated, move to another area where there is plenty of clean, fresh air to breath. If the irritation is not alleviated by these actions, contact a physician immediately. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag Air Bag: Service and Repair Driver Airbag Removal and Installation REMOVAL The following procedure is for replacement of a faulty or damaged driver airbag. If the driver airbag has been deployed, the clockspring and the steering column assembly must also be replaced. (Refer to CLOCKSPRING - REMOVAL). WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - WHEN REMOVING A DEPLOYED AIRBAG, RUBBER GLOVES, EYE PROTECTION, AND A LONG-SLEEVED SHIRT SHOULD BE WORN. THERE MAY BE DEPOSITS ON THE AIRBAG CUSHION 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 either of the airbags has not been deployed, wait two minutes for the system capacitor to discharge before further service. Fig. 12 Driver Airbag Remove/Install 2. From the underside of the steering wheel, remove the two screws that secure the driver airbag to the steering wheel armature. 3. Pull the driver airbag away from the steering wheel far enough to access the two wire harness connectors at the back of the airbag. 4. Disconnect the steering wheel wire harness connector for the horn switch from the horn switch feed pigtail wire connector, which is located at the back of the driver airbag. CAUTION: Do not pull on the clockspring pigtail wire to disengage the connector from the driver air- bag inflator connector receptacle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 6149 5. The clockspring driver airbag pigtail wire connector is a tight snap-fit into the airbag inflator connector receptacle, which is located at the back of the driver airbag. Firmly grasp and pull or gently pry on the clockspring driver airbag wire harness connector to disconnect it from the airbag inflator connector receptacle. 6. Remove the driver airbag from the steering wheel. 7. If the driver airbag has been deployed, the clockspring and the steering column must be replaced. (Refer to CLOCKSPRING - REMOVAL). (Refer to STEERING/COLUMN - REMOVAL). INSTALLATION The following procedure is for replacement of a faulty or damaged driver airbag. If the driver airbag has been deployed, the clockspring and the steering column assembly must also be replaced. (Refer to CLOCKSPRING - REMOVAL) and (Refer to STEERING/COLUMN - REMOVAL). WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE DRIVER AIRBAG, OR BECOMING ENTRAPPED BETWEEN THE DRIVER AIRBAG CUSHION AND THE DRIVER AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. - THE DRIVER AIRBAG TRIM COVER MUST NEVER BE PAINTED. REPLACEMENT TRIM COVERS ARE SERVICED IN THE ORIGINAL COLORS. PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE TRIM COVER RESPONDS TO AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. 1. Assemble the driver airbag trim cover onto the airbag housing. (Refer to RESTRAINTS/DRIVER AIRBAG - ASSEMBLY). 2. When installing the driver airbag, reconnect the clockspring driver airbag pigtail wire connector to the airbag inflator connector receptacle by pressing straight in on the connector. You can be certain that the connector is fully engaged by listening carefully for a distinct, audible click as the connector snaps into place. 3. Reconnect the steering wheel wire harness connector for the horn switch to the horn switch feed pigtail wire connector, which is located at the back of the driver airbag. 4. Carefully position the driver airbag in the steering wheel. Be certain that the clockspring pigtail wire and steering wheel wire harness in the steering wheel hub area are not pinched between the driver airbag and the steering wheel armature. 5. From the underside of the steering wheel, install and tighten the two screws that secure the driver airbag to the steering wheel armature. Tighten the screws to 10 Nm (90 in. lbs.). 6. Do not reconnect the battery negative cable at this time. The airbag system verification test procedure should be performed following service of any airbag system component. (Refer to RESTRAINTS - STANDARD PROCEDURE VERIFICATION TEST). Disassembly and Assembly DISASSEMBLY The following procedures can be used to replace the driver airbag trim cover or the horn switch and tray unit. If the driver airbag is faulty or deployed, the entire driver airbag, trim cover, and horn switch must be replaced as a unit. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE HORN SWITCH IS INTEGRAL TO THE DRIVER AIRBAG UNIT. SERVICE OF THIS UNIT SHOULD BE PERFORMED ONLY BY DAIMLERCHRYSLER-TRAINED AND AUTHORIZED DEALER SERVICE TECHNICIANS. FAILURE TO TAKE THE PROPER PRECAUTIONS OR TO FOLLOW THE PROPER PROCEDURES COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. 1. Disconnect and isolate the battery negative cable. If either of the airbags has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Remove the driver airbag from the steering wheel (Refer to RESTRAINTS/DRIVER AIRBAG REMOVAL). 3. Using hand pressure, press the airbag housing down into the receptacle on the back of the driver airbag trim cover. 4. Carefully pry back the walls of the driver air- bag receptacle on the back of the trim cover to release each of the twelve windows of the trim cover receptacle from the twelve hook formations on the perimeter of the airbag housing. 5. Remove the housing, inflator, cushion, and horn switch as a unit from the driver airbag trim cover receptacle. 6. Gently pry off the plastic wire retainer that captures the horn switch feed pigtail wire between the upper right inflator stud and the inflator on the back of the driver airbag housing. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 6150 7. Remove the nut and washer that secures the horn switch ground pigtail wire eyelet terminal to the upper left inflator stud on the back of the driver airbag housing. 8. Remove the horn switch ground pigtail wire eyelet terminal from the upper left inflator stud on the back of the driver airbag housing. 9. Slide the horn switch and tray unit all the way to one side of the pouch on the driver airbag cushion retainer strap to disengage one of the retaining tabs on the tray from one of the slits located in each side of the pouch. Fig.13 Horn Switch Remove/Install 10. Remove the horn switch and tray as a unit from the pouch on the driver airbag cushion retainer strap. ASSEMBLY The following procedures can be used to replace the driver airbag trim cover or the horn switch and tray unit. If the driver airbag is faulty or deployed, the entire driver airbag, trim cover, and horn switch must be replaced as a unit. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE HORN SWITCH IS INTEGRAL TO THE DRIVER AIRBAG UNIT. SERVICE OF THIS UNIT SHOULD BE PERFORMED ONLY BY DAIMLERCHRYSLER-TRAINED AND AUTHORIZED DEALER SERVICE TECHNICIANS. FAILURE TO TAKE THE PROPER PRECAUTIONS OR TO FOLLOW THE PROPER PROCEDURES COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. - USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE DRIVER AIRBAG, OR BECOMING ENTRAPPED BETWEEN THE DRIVER AIRBAG CUSHION AND THE DRIVER AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. - THE DRIVER AIRBAG TRIM COVER MUST NEVER BE PAINTED. REPLACEMENT TRIM COVERS ARE SERVICED IN THE ORIGINAL COLORS. PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE TRIM COVER RESPONDS TO AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 6151 Fig. 14 Horn Switch Installed 1. Install the horn switch and tray unit into the pouch on the driver airbag cushion retainer strap. Be certain that the tray is facing the airbag cushion, that the horn switch membrane is facing the airbag trim cover, that the horn switch feed pigtail wire is on the right, that the horn switch ground pigtail wire is on the left, and that the retaining tabs on the tray are each engaged in one of the slits located in each side of the pouch 2. Route the horn switch ground pigtail wire through the clearance notch between the two upper left hooks on the driver airbag housing. Install the eyelet terminal over the upper left inflator stud and engage the terminal under the anti-rotation tab directly above the stud on the back of the driver airbag housing. 3. Install and tighten the nut and washer that secure the horn switch ground pigtail wire eyelet terminal to the upper left inflator stud on the back of the driver airbag housing. Tighten the nut to 7 Nm (65 in. lbs.). 4. Route the horn switch feed pigtail wire through the clearance notch between the two upper right hooks and between the upper right inflator stud and the inflator on the back of the driver airbag housing. 5. Using hand pressure, press the plastic wire retainer onto the upper right inflator stud to capture the horn switch feed pigtail wire between the stud and the inflator on the back of the driver airbag housing. 6. Carefully position the driver airbag into the receptacle on the back of the trim cover. Be certain that the horn switch feed and ground pigtail wires remain properly routed through the clearance notches at the top of the airbag housing and are not pinched between the airbag housing and the walls of the trim cover receptacle. 7. Work around the perimeter of the unit engaging each of the twelve hooks on the driver airbag housing through the windows in the walls of the trim cover receptacle. 8. After each of the twelve hooks on the driver airbag housing has been engaged in a window of the trim cover receptacle, try pulling the trim cover and the airbag housing away from each other. This action will fully seat the edges of the windows into the cradles of the hooks. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 6152 Fig. 15 Driver Airbag Trim Cover Side Blocking Tabs 9. After all of the windows in the walls of the trim cover receptacle have been fully seated in the cradles of the hooks on the airbag housing, push the blocking tabs of the two windows on the right and left side walls of the trim cover receptacle inward so that they are oriented behind the airbag housing hooks, as shown in. Fig. 16 Driver Airbag Trim Cover Upper & Lower Blocking Tabs 10. Inspect the airbag housing hooks in the windows of the upper and lower walls of the trim cover receptacle to be certain they are fully engaged and that the blocking tabs for these windows are oriented over the tops of the hooks, as shown in. 11. Reinstall the driver airbag onto the steering wheel (Refer to RESTRAINTS/ DRIVER AIRBAG INSTALLATION). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 6153 Air Bag: Service and Repair Passenger Airbag REMOVAL WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - WHEN REMOVING A DEPLOYED AIRBAG, RUBBER GLOVES, EYE PROTECTION, AND A LONG-SLEEVED SHIRT SHOULD BE WORN. THERE MAY BE DEPOSITS ON THE AIRBAG UNIT 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 either of the airbags has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Remove the glove box module from the instrument panel. 3. Remove the radio from the instrument panel (Refer to RADIO - REMOVAL). Fig. 20 Passenger Airbag Connector 4. Reach through the radio opening in the instrument panel to access and disconnect the instrument panel wire harness connector for the passenger airbag from the passenger airbag pigtail wire connector on the instrument panel armature to the left of the glove box opening. 5. Disengage the passenger airbag pigtail wire connector retainers from the instrument panel armature. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 6154 Fig. 21 Passenger Airbag Mounting 6. Working through the glove box opening, remove the two screws that secure the passenger airbag front brackets to the instrument panel armature. 7. Remove the two screws that secure the passenger airbag rear brackets to the glove box opening upper reinforcement. 8. Using a trim stick or another suitable wide flatbladed tool, gently pry the top of the passenger airbag door away from the instrument panel far enough to disengage the five snap features on the airbag door from their receptacles in the instrument panel. 9. Remove the passenger airbag and airbag door from the instrument panel as a unit. INSTALLATION WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - WHEN REMOVING A DEPLOYED AIRBAG, RUBBER GLOVES, EYE PROTECTION, AND A LONG-SLEEVED SHIRT SHOULD BE WORN. THERE MAY BE DEPOSITS ON THE AIRBAG UNIT AND OTHER INTERIOR SURFACES. IN LARGE DOSES, THESE DEPOSITS MAY CAUSE IRRITATION TO THE SKIN AND EYES. - USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE PASSENGER AIRBAG, OR BECOMING ENTRAPPED BETWEEN THE PASSENGER AIRBAG CUSHION AND THE PASSENGER AIRBAG DOOR. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. - THE PASSENGER AIRBAG DOOR MUST NEVER BE PAINTED. REPLACEMENT PASSENGER AIRBAG DOORS ARE SERVICED IN THE ORIGINAL COLORS. PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE AIRBAG DOOR RESPONDS TO AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. 1. Carefully position the passenger airbag into the instrument panel. 2. Align the five snap features on the upper edge of the passenger airbag door with the receptacles in the instrument panel top cover. 3. Using hand pressure, press firmly on the passenger airbag door over each of the snap feature locations until each of them is fully engaged in its receptacle. 4. Install and tighten the two screws that secure the passenger airbag rear brackets to the glove box opening upper reinforcement. Tighten the screws to 9 Nm (80 in. lbs.). 5. Working through the glove box opening, install and tighten the two screws that secure the passenger airbag front brackets to the instrument panel armature. Tighten the screws to 9 Nm (80 in. lbs.). 6. Reach through the radio opening in the instrument panel to access and reconnect the instrument panel wire harness connector for the passenger airbag to the passenger airbag pigtail wire connector. Be certain that the passenger airbag pigtail wire connector is fully engaged with and latched to the instrument panel wire harness connector. 7. Engage the passenger airbag pigtail wire connector retainers in the mounting holes provided on the instrument panel armature. 8. Reinstall the radio into the instrument panel (Refer to RADIO INSTALLATION). 9. Reinstall the glove box module onto the instrument panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 6155 10. Do not reconnect the battery negative cable at this time. The airbag system verification test procedure should be performed following service of any airbag system component. (Refer to RESTRAINTS - STANDARD PROCEDURE VERIFICATION TEST). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Module Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6159 Airbag Control Module Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6160 Air Bag Control Module: Service Precautions WARNING: - DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONERS, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAGS. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6161 Air Bag Control Module: Description and Operation The Airbag Control Module (ACM) is secured with screws to a mount welded onto the top of the floor panel transmission tunnel behind the instrument panel center support bracket in the passenger compartment of the vehicle. The ACM contains an electronic microprocessor, an electronic impact sensor, an electromechanical safing sensor, and an energy storage capacitor. The ACM is connected to the vehicle electrical system through a take out and connector of the instrument panel wire harness. The ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. The microprocessor in the ACM contains the airbag system logic circuits, and it monitors and controls all of the airbag system components. The ACM also uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the DRB III scan tool using the Programmable Communications Interface (PCI) data bus network. This method of communication is used for control of the airbag indicator in the ElectroMechanical Instrument Cluster (EMIC) and for airbag system diagnosis and testing through the 16-way data link connector located on the lower left edge of the instrument panel. (Refer to INSTRUMENT CLUSTER/AIRBAG INDICATOR - OPERATION). The ACM microprocessor continuously monitors all of the airbag system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sets an active Diagnostic Trouble Code (DTC) and sends messages to the EMIC over the PCI data bus to turn ON the airbag indicator. If the airbag system fault is still present when the ignition switch is turned to the OFF position, the DTC is stored in memory by the ACM. However, if a fault does not recur for a number of ignition cycles, the ACM will automatically erase the stored DTC. The ACM receives battery current through two circuits, on a fused ignition switch output (run) circuit through a fuse in the Junction Block (JB), and on a fused ignition switch output (run-start) circuit through a second fuse in the JB. The ACM is grounded through a ground circuit and take out of the instrument panel wire harness. This take out has a single eyelet terminal connector secured by a ground screw to the left side of the floor panel transmission tunnel near the ACM in the passenger compartment. Therefore, the ACM is operational whenever the ignition switch is in the Start or ON positions. The ACM also contains an energy-storage capacitor. When the ignition switch is in the Start or ON positions, this capacitor is continually being charged with enough electrical energy to deploy the airbags for up to one second following a battery disconnect or failure. The purpose of the capacitor is to provide backup airbag system protection in case there is a loss of battery current supply to the ACM during an impact. The capacitor is only serviced as a unit with the ACM. Two sensors are contained within the ACM, an electronic impact sensor and a safing sensor. The electronic impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. A pre-programmed decision algorithm in the ACM microprocessor determines when the deceleration rate as signaled by the impact sensor 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 airbags and the seat belt tensioners. The safing sensor is an electromechanical sensor within the ACM that is connected in series between the ACM microprocessor deployment circuit and the airbags/seat belt tensioners. The safing sensor is a normally open switch that is used to verify or confirm the need for an airbag deployment by detecting impact energy of a lesser magnitude than that of the electronic impact sensor, and must be closed in order for the airbags/seat belt tensioners to deploy. The impact sensor and safing sensor are calibrated for the specific vehicle, and are only serviced as a unit with the ACM. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6162 Air Bag Control Module: Service and Repair REMOVAL WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONERS, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAGS. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. 1. Disconnect and isolate the battery negative cable. If either of the airbags has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. From the right side of the floor panel transmission tunnel, remove the screw that secures the floor duct adapter to the bottom of the heater-air conditioner housing. 3. Remove the floor duct adapter from the bottom of the heater-air conditioner housing. 4. Pull the carpet on the right and left sides of the floor panel transmission tunnel rearward far enough to access the Airbag Control Module (ACM). Fig. 5 Airbag Control Module 5. Remove the two screws that secure the ACM to the right side of the mounting bracket that is welded onto the floor panel transmission tunnel. 6. Remove the two screws that secure the ACM to the left side of the mounting bracket that is welded onto the floor panel transmission tunnel. 7. Lift the ACM upward from the mounting bracket far enough to disengage the locator pins on the ACM housing from the locator holes in the mounting bracket, then pull the ACM out from under the instrument panel far enough to access the wire harness connector. 8. Disconnect the instrument panel wire harness connector for the ACM from the ACM connector receptacle. To disconnect the instrument panel wire harness connector for the ACM: a. Slide the red Connector Position Assurance (CPA) lock on the top of the connector toward the right side of the vehicle. b. Depress the latch tab on the upper surface of the connector, and pull the connector straight away from the ACM connector receptacle. 9. Remove the ACM from beneath the instrument panel. INSTALLATION WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONERS, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6163 DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAGS. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. 1. Position the Airbag Control Module (ACM) beneath the instrument panel. 2. Reconnect the instrument panel wire harness connector for the ACM to the ACM connector receptacle. Be certain that the connector latch and the red Connector Position Assurance (CPA) lock are fully engaged. 3. Carefully position the ACM to the mounting bracket that is welded onto the floor panel transmission tunnel. When the ACM is correctly positioned, the locator pins on the ACM housing will be engaged in the locator holes in the mounting bracket, and the arrow on the ACM label will be pointed forward in the vehicle. 4. Install and tighten the two screws that secure the ACM to the right side of the mounting bracket that is welded onto the floor panel transmission tunnel. Tighten the screws to 12 Nm (105 in. lbs.). 5. Install and tighten the two screws that secure the ACM to the left side of the mounting bracket that is welded onto the floor panel transmission tunnel. Tighten the screws to 12 Nm (105 in. lbs.). 6. Restore the carpet on the right and left sides of the floor panel transmission tunnel to its proper position beneath the instrument panel. 7. From the right side of the floor panel transmission tunnel, position the floor duct adapter onto the bottom of the heater-air conditioner housing. 8. Install and tighten the screw that secures the floor duct adapter to the bottom of the heater-air conditioner housing. Tighten the screw to 2 Nm (17 in. lbs.). 9. Do not reconnect the battery negative cable at this time. The airbag system verification test procedure should be performed following service of any airbag system component. (Refer to RESTRAINTS - STANDARD PROCEDURE VERIFICATION TEST). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6168 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6169 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6170 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6171 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6172 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6173 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service > Page 6178 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 6179 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 6180 Clockspring Assembly / Spiral Cable: Diagrams Clockspring C1 Clockspring C2 Clockspring C3 Clockspring C4 (Premium Radio) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 6181 Clockspring Assembly / Spiral Cable: Service Precautions WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 6182 Clockspring Assembly / Spiral Cable: Description and Operation Fig. 7 Clockspring And Multi-Function Switch The clockspring assembly is secured with two screws onto the multi-function switch mounting housing near the top of the steering column behind the steering wheel. The clockspring consists of a flat, round molded plastic case with a stubby tail that hangs below the steering column and contains two connector receptacles that face toward the instrument panel. Within the plastic housing is a spool-like molded plastic rotor with a large exposed hub. The upper surface of the rotor hub has a large center hole, two large flats, an engagement dowel with a yellow rubber boot, a short pigtail wire with connector, and two connector receptacles that face toward the steering wheel. The lower surface of the rotor hub has a molded plastic turn signal cancel cam with two lobes that is keyed to the rotor and is secured there with four integral snap features. Within the plastic case and wound around the rotor spool is a long ribbon-like tape that consists of several thin copper wire leads sandwiched between two thin plastic membranes. The outer end of the tape terminates at the connector receptacles that face the instrument panel, while the inner end of the tape terminates at the pigtail wire and connector receptacles on the hub of the clockspring rotor that face the steering wheel. Service replacement clocksprings are shipped pre-centered and with a locking pin that snaps into a receptacle on the rotor and is engaged between two tabs on the upper surface of the rotor case. The locking pin secures the centered clockspring rotor to the clockspring case during shipment, but the locking pin must be removed from the clockspring after it is installed on the steering column. (Refer to CLOCKSPRING - STANDARD PROCEDURE - CLOCKSPRING CENTERING). The clockspring cannot be repaired. If the clockspring is faulty, damaged, or if the driver airbag has been deployed, the clockspring must be replaced. The clockspring is a mechanical electrical circuit component that is used to provide continuous electrical continuity between the fixed instrument panel wire harness and the electrical components mounted on or in the rotating steering wheel. On this model the rotating electrical components include the driver airbag, the horn switch, the speed control switches, and the remote radio switches if the vehicle is so equipped. The clockspring case is positioned and secured to the multi-function switch mounting housing near the top of the steering column. The connector receptacles on the tail of the fixed clockspring case connect the clockspring to the vehicle electrical system through two take outs with connectors from the instrument panel wire harness. The clockspring rotor is movable and is keyed by an engagement dowel that is molded onto the rotor hub between two fins that are cast into the lower surface of the steering wheel armature. A yellow rubber boot is installed over the engagement dowel to eliminate noise. The two lobes on the turn signal cancel cam on the lower surface of the clockspring rotor hub contact a turn signal cancel actuator of the multi-function switch to provide automatic turn signal cancellation. The yellow sleeved pigtail wires on the upper surface of the clockspring rotor connect the clockspring to the driver airbag, while a steering wheel wire harness connects the two connector receptacles on the upper surface of the clockspring rotor to the horn switch and, if the vehicle is so equipped, to the optional speed control and remote radio switches on the steering wheel. Like the clockspring in a timepiece, the clockspring tape has travel limits and can be damaged by being wound too tightly during full stop-to-stop steering wheel rotation. To prevent this from occurring, the clockspring is centered when it is installed on the steering column. Centering the clockspring indexes the clockspring tape to the movable steering components so that the tape can operate within its designed travel limits. However, if the clockspring is removed from the steering column or if the steering shaft is disconnected from the steering gear, the clockspring spool can change position Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 6183 relative to the movable steering components and must be re-centered following completion of the service or the tape may be damaged. Service replacement clocksprings are shipped pre-centered and with a plastic locking pin installed. This locking pin should not be disengaged until the clockspring has been installed on the steering column. If the locking pin is removed or damaged before the clockspring is installed on a steering column, the clockspring centering procedure must be performed. (Refer to CLOCKSPRING - STANDARD PROCEDURE - CLOCKSPRING CENTERING). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 6184 Clockspring Assembly / Spiral Cable: Adjustments The clockspring is designed to wind and unwind when the steering wheel is rotated, but is only designed to rotate the same number of turns (about five complete rotations) as the steering wheel can be turned from stop to stop. Centering the clockspring indexes the clockspring tape to other steering components so that it can operate within its designed travel limits. The rotor of a centered clockspring can be rotated two and one-half turns in either direction from the centered position, without damaging the clockspring tape. Fig. 7 Clockspring And Multi-Function Switch However, if the clockspring is removed for service or if the steering column is disconnected from the steering gear, the clockspring tape can change position relative to the other steering components. The clockspring must then be re-centered following completion of such service or the clockspring tape may be damaged. Service replacement clocksprings are shipped pre-centered and with a plastic locking pin installed. This locking pin should not be removed until the clockspring has been installed on the steering column. If the locking pin is removed before the clockspring is installed on a steering column, the clockspring centering procedure must be performed. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: Before starting this procedure, be certain to turn the steering wheel until the front wheels are in the straight-ahead position. 1. Place the front wheels in the straight-ahead position. 2. Remove the clockspring from the steering column (Refer to CLOCKSPRING - REMOVAL). 3. Rotate the clockspring rotor clockwise to the end of its travel. Do not apply excessive torque. 4. From the end of the clockwise travel, rotate the rotor about two and one-half turns counterclockwise. The engagement dowel and yellow rubber boot should end up at the bottom, and the arrows on the clockspring rotor and case should be in alignment. The clockspring is now centered. 5. The front wheels should still be in the straight- ahead position. Reinstall the clockspring onto the steering column (Refer to CLOCKSPRING INSTALLATION). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 6185 Clockspring Assembly / Spiral Cable: Service and Repair REMOVAL The clockspring cannot be repaired. It must be replaced if faulty or damaged, or if the driver airbag has been deployed. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: Before starting this procedure, be certain to turn the steering wheel until the front wheels are in the straight-ahead position. 1. Place the front wheels in the straight-ahead position. 2. Remove the driver airbag from the steering wheel (Refer to RESTRAINTS/ DRIVER AIRBAG - REMOVAL). 3. Disconnect the steering wheel wire harness connectors from the upper clockspring connector receptacles. 4. Remove the screw that secures the steering wheel armature to the steering column upper shaft, which is located within the hub cavity of the steering wheel. CAUTION: Be certain that the screws that secure the steering wheel puller to the steering wheel are fully engaged in the steering wheel armature without passing through the steering wheel and damaging the clockspring. 5. Pull the steering wheel off of the steering column upper shaft spline using a steering wheel puller (Special Tool C-3428-B). 6. Remove the steering column opening cover from the instrument panel. 7. If the vehicle is so equipped, grasp the tilt steering column knob firmly and pull it straight rearward to remove it from the tilt steering column adjuster mechanism lever located on the left side of the column just below the multi-function switch control stalk. 8. From below the steering column, remove the two outboard screws that secure the upper shroud to the lower shroud. 9. Push gently inward on both sides of the upper shroud near the parting line between the upper and lower shrouds to release the snap features that secure it to the lower shroud. 10. Remove the upper shroud from the lower shroud. 11. From below the steering column, remove the one center screw that secures the lower shroud to the steering column lock housing. 12. Remove the lower shroud from the steering column. 13. Disconnect the two instrument panel wire harness connectors for the clockspring from the lower clockspring connector receptacles. Fig. 7 Clockspring And Multi-Function Switch 14. Remove the two screws that secure the clock- spring to the multi-function switch mounting housing. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 6186 15. Remove the clockspring from the multi-function switch mounting housing. The clockspring cannot be repaired. It must be replaced if faulty or damaged, or if the driver airbag has been deployed. 16. If the removed clockspring is to be reused, secure the clockspring rotor to the clockspring case to maintain clockspring centering until it is reinstalled on the steering column. If clockspring centering is not maintained, the clockspring must be centered again before it is reinstalled. (Refer to CLOCKSPRING - STANDARD PROCEDURE CLOCKSPRING CENTERING). INSTALLATION The clockspring cannot be repaired. It must be replaced if faulty or damaged, or if the driver airbag has been deployed. If the clockspring is not properly centered in relation to the steering wheel, steering shaft and steering gear, it may be damaged. (Refer to CLOCKSPRING - STANDARD PROCEDURE CLOCKSPRING CENTERING). Service replacement clocksprings are shipped pre-centered and with a plastic locking pin installed. This locking pin should not be removed until the clockspring has been installed on the steering column. If the locking pin is removed before the clockspring is installed on a steering column, the clockspring centering procedure must be performed. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: Before starting this procedure, be certain that the front wheels are still in the straight-ahead position. 1. Carefully slide the centered clockspring down over the steering column upper shaft until the hole in the locating tab at the eleven o'clock position on the clockspring case is engaged over the locating pin on the multi-function switch mounting housing. 2. Install and tighten the two screws that secure the clockspring to the multi-function switch mounting housing. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the two instrument panel wire harness connectors for the clockspring to the lower clock-spring connector receptacles. 4. Position the lower shroud onto the steering column. 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column lock housing. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud onto the steering column. If the vehicle is equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the openings in the right side of the upper and lower shrouds. 7. Align the snap features on the upper shroud with the receptacles on the lower shroud and apply hand pressure to snap them together. 8. From below the steering column, install and tighten the two screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). 9. If the vehicle is so equipped, align the tilt steering column knob with the tilt steering column adjuster mechanism lever located on the left side of the column just below the multi-function switch control stalk and using hand pressure push the knob firmly onto the lever. 10. Reinstall the steering column opening cover onto the instrument panel. 11. Reinstall the steering wheel onto the steering column upper shaft. Be certain to index the yellow rubber booted engagement dowel on the upper surface of the clockspring rotor between the two fins cast into the lower surface of the steering wheel armature hub. Pull the upper clockspring pigtail wire through the upper hole between the steering wheel back trim cover and the steering wheel armature. 12. Install and tighten the screw that secures the steering wheel to the steering column upper shaft. Tighten the screw to 61 Nm (45 ft. lbs.). Be certain not to pinch the clockspring pigtail wire or the steering wheel wire harness between the steering wheel and the screw. 13. Reconnect the steering wheel wire harness connectors to the upper clockspring connector receptacles. Be certain that the steering wire harness is routed between the steering wheel back trim cover and the steering wheel armature. 14. Reinstall the driver airbag onto the steering wheel. (Refer to RESTRAINTS/DRIVER AIRBAG INSTALLATION). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Locations Malfunction Lamp / Indicator: Locations The airbag indicator is located in the Information Center area of the instrument cluster, to the right of center. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Locations > Page 6190 Malfunction Lamp / Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Airbag .................................................................................................................................................. ............................................................... PC194 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Locations > Page 6191 Malfunction Lamp / Indicator: Description and Operation AIRBAG INDICATOR An airbag indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with airbags, this indicator is electronically disabled. The airbag indicator is located in the Information Center area of the instrument cluster, to the right of center. The airbag indicator consists of a stenciled cutout of the word "AIRBAG" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red lens behind the cutout in the opaque layer of the overlay causes the "AIRBAG" text to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by a Light Emitting Diode (LED) soldered onto the instrument cluster electronic circuit board. The airbag indicator is serviced as a unit with the instrument cluster. The airbag indicator gives an indication to the vehicle operator when the airbag system is faulty or inoperative. The airbag indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Airbag Control Module (ACM) over the Programmable Communications Interface (PCI) data bus. The airbag indicator Light Emitting Diode (LED) receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions; therefore, the indicator will always be OFF when the ignition switch is in any position except ON or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the airbag indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the airbag indicator is illuminated for about seven seconds. The first two seconds is the cluster bulb test function, and the remainder is the ACM bulb test function. - ACM Lamp-ON Message - Each time the cluster receives a lamp-ON message from the ACM, the airbag indicator will be illuminated. The indicator remains illuminated for about twelve seconds or until the cluster receives a lamp-OFF message from the ACM, whichever is longer. - Communication Error - If the cluster receives no airbag messages for three consecutive seconds, the airbag indicator is illuminated. The indicator remains illuminated for about twelve seconds or until the cluster receives a single lamp-OFF message from the ACM, whichever is longer. - Actuator Test - Each time the cluster is put through the actuator test, the airbag indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The ACM continually monitors the airbag system circuits and sensors to decide whether the system is in good operating condition. The ACM then sends the proper lamp-ON or lamp-OFF messages to the instrument cluster. If the ACM sends a lamp-ON message after the bulb test, it indicates that the ACM has detected a system malfunction and/or that the airbags may not deploy when required, or may deploy when not required. The ACM will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the airbag indicator fails to illuminate due to an open or short in the cluster airbag indicator circuit, the cluster sends a message notifying the ACM of the condition. The ACM will store a DTC and the cluster will begin blinking the seat belt indicator. (Refer to SEATBELT INDICATOR - OPERATION). For proper diagnosis of the airbag system, the ACM, the PCI data bus, or the message inputs to the instrument cluster that control the airbag indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Module Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6196 Airbag Control Module Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6197 Air Bag Control Module: Service Precautions WARNING: - DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONERS, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAGS. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6198 Air Bag Control Module: Description and Operation The Airbag Control Module (ACM) is secured with screws to a mount welded onto the top of the floor panel transmission tunnel behind the instrument panel center support bracket in the passenger compartment of the vehicle. The ACM contains an electronic microprocessor, an electronic impact sensor, an electromechanical safing sensor, and an energy storage capacitor. The ACM is connected to the vehicle electrical system through a take out and connector of the instrument panel wire harness. The ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. The microprocessor in the ACM contains the airbag system logic circuits, and it monitors and controls all of the airbag system components. The ACM also uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the DRB III scan tool using the Programmable Communications Interface (PCI) data bus network. This method of communication is used for control of the airbag indicator in the ElectroMechanical Instrument Cluster (EMIC) and for airbag system diagnosis and testing through the 16-way data link connector located on the lower left edge of the instrument panel. (Refer to INSTRUMENT CLUSTER/AIRBAG INDICATOR - OPERATION). The ACM microprocessor continuously monitors all of the airbag system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sets an active Diagnostic Trouble Code (DTC) and sends messages to the EMIC over the PCI data bus to turn ON the airbag indicator. If the airbag system fault is still present when the ignition switch is turned to the OFF position, the DTC is stored in memory by the ACM. However, if a fault does not recur for a number of ignition cycles, the ACM will automatically erase the stored DTC. The ACM receives battery current through two circuits, on a fused ignition switch output (run) circuit through a fuse in the Junction Block (JB), and on a fused ignition switch output (run-start) circuit through a second fuse in the JB. The ACM is grounded through a ground circuit and take out of the instrument panel wire harness. This take out has a single eyelet terminal connector secured by a ground screw to the left side of the floor panel transmission tunnel near the ACM in the passenger compartment. Therefore, the ACM is operational whenever the ignition switch is in the Start or ON positions. The ACM also contains an energy-storage capacitor. When the ignition switch is in the Start or ON positions, this capacitor is continually being charged with enough electrical energy to deploy the airbags for up to one second following a battery disconnect or failure. The purpose of the capacitor is to provide backup airbag system protection in case there is a loss of battery current supply to the ACM during an impact. The capacitor is only serviced as a unit with the ACM. Two sensors are contained within the ACM, an electronic impact sensor and a safing sensor. The electronic impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. A pre-programmed decision algorithm in the ACM microprocessor determines when the deceleration rate as signaled by the impact sensor 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 airbags and the seat belt tensioners. The safing sensor is an electromechanical sensor within the ACM that is connected in series between the ACM microprocessor deployment circuit and the airbags/seat belt tensioners. The safing sensor is a normally open switch that is used to verify or confirm the need for an airbag deployment by detecting impact energy of a lesser magnitude than that of the electronic impact sensor, and must be closed in order for the airbags/seat belt tensioners to deploy. The impact sensor and safing sensor are calibrated for the specific vehicle, and are only serviced as a unit with the ACM. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6199 Air Bag Control Module: Service and Repair REMOVAL WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONERS, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAGS. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. 1. Disconnect and isolate the battery negative cable. If either of the airbags has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. From the right side of the floor panel transmission tunnel, remove the screw that secures the floor duct adapter to the bottom of the heater-air conditioner housing. 3. Remove the floor duct adapter from the bottom of the heater-air conditioner housing. 4. Pull the carpet on the right and left sides of the floor panel transmission tunnel rearward far enough to access the Airbag Control Module (ACM). Fig. 5 Airbag Control Module 5. Remove the two screws that secure the ACM to the right side of the mounting bracket that is welded onto the floor panel transmission tunnel. 6. Remove the two screws that secure the ACM to the left side of the mounting bracket that is welded onto the floor panel transmission tunnel. 7. Lift the ACM upward from the mounting bracket far enough to disengage the locator pins on the ACM housing from the locator holes in the mounting bracket, then pull the ACM out from under the instrument panel far enough to access the wire harness connector. 8. Disconnect the instrument panel wire harness connector for the ACM from the ACM connector receptacle. To disconnect the instrument panel wire harness connector for the ACM: a. Slide the red Connector Position Assurance (CPA) lock on the top of the connector toward the right side of the vehicle. b. Depress the latch tab on the upper surface of the connector, and pull the connector straight away from the ACM connector receptacle. 9. Remove the ACM from beneath the instrument panel. INSTALLATION WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONERS, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6200 DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAGS. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. 1. Position the Airbag Control Module (ACM) beneath the instrument panel. 2. Reconnect the instrument panel wire harness connector for the ACM to the ACM connector receptacle. Be certain that the connector latch and the red Connector Position Assurance (CPA) lock are fully engaged. 3. Carefully position the ACM to the mounting bracket that is welded onto the floor panel transmission tunnel. When the ACM is correctly positioned, the locator pins on the ACM housing will be engaged in the locator holes in the mounting bracket, and the arrow on the ACM label will be pointed forward in the vehicle. 4. Install and tighten the two screws that secure the ACM to the right side of the mounting bracket that is welded onto the floor panel transmission tunnel. Tighten the screws to 12 Nm (105 in. lbs.). 5. Install and tighten the two screws that secure the ACM to the left side of the mounting bracket that is welded onto the floor panel transmission tunnel. Tighten the screws to 12 Nm (105 in. lbs.). 6. Restore the carpet on the right and left sides of the floor panel transmission tunnel to its proper position beneath the instrument panel. 7. From the right side of the floor panel transmission tunnel, position the floor duct adapter onto the bottom of the heater-air conditioner housing. 8. Install and tighten the screw that secures the floor duct adapter to the bottom of the heater-air conditioner housing. Tighten the screw to 2 Nm (17 in. lbs.). 9. Do not reconnect the battery negative cable at this time. The airbag system verification test procedure should be performed following service of any airbag system component. (Refer to RESTRAINTS - STANDARD PROCEDURE VERIFICATION TEST). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 6205 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service Precautions Child Seat Tether Attachment: Service Precautions WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW, AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service Precautions > Page 6210 Child Seat Tether Attachment: Service and Repair REMOVAL WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW, AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. Fig. 6 Child Tether Anchors 1. Remove the screw that secures the child tether anchor loop to the liftgate opening sill panel or rear floor panel. 2. Remove the child tether anchor loop from the liftgate opening sill panel or rear floor panel. INSTALLATION WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. 1. Position the child tether anchor loop onto the liftgate opening sill panel or rear floor panel. 2. Install and tighten the screw that secures the child tether anchor loop onto the liftgate opening sill panel or rear floor panel. Tighten the screw to 23 Nm (17 ft. lbs.). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Interior - Seat Belt Cinch Bar Service Seat Belt: Technical Service Bulletins Interior - Seat Belt Cinch Bar Service NUMBER: 08-010-03 GROUP: Electrical DATE: Apr.25, 2003 SUBJECT: Seat Belt Cinch Bar Service MODELS: 2001 - 2003 (AB) Ram Van/Wagon (Front Passenger Seat Belt Only) 1994 (BR) Ram Pickup 1996-2002 (BR/BE) Ram Pickup 2001 - 2003 (DN) Durango (Front Passenger Seat Belt Only) 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 1996 - 2000 (JX) Sebring Convertible 1995 - 2003 (PL) Neon/SX 2.0 2001 - 2003 (PT) PT Cruiser DISCUSSION: Any time the seat belt cinch bar (Fig. 1) is loose, missing or damaged it is no longer necessary to replace the seat belt assembly. Cinch bar repair kits are now available for the vehicles listed. If any component of the seat belt assembly has been damaged due to collision, the entire assembly must be replaced. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Interior - Seat Belt Cinch Bar Service > Page 6215 NOTE: THE CINCH BAR, CINCH BAR COVER OR ANY OTHER COMPONENT OF THE SEAT BELT ASSEMBLY MUST NEVER BE PAINTED. NOTE: INSTALLATION INSTRUCTIONS ARE INCLUDED WITH EACH KIT. PARTS REQUIRED: NOTE: SELECT THE COLOR CLOSEST TO THE SEAT BELT ASSEMBLY COLOR. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Page 6216 Seat Belt: Service Precautions WARNING: - ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt and Retractor - Front Seat Seat Belt: Service and Repair Seat Belt and Retractor - Front Seat REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. 1. Move the front seats to their most forward position for easiest access to the lower seat belt anchor plate, the retractor, and the B-pillar. 2. Disconnect and isolate the battery negative cable. If either of the airbags has not been deployed, wait two minutes for the system capacitor to discharge before further service. 3. Lift the cover on the lower seat belt anchor plate far enough to access the screw that secures the anchor plate to the front seat adjuster. Fig.17 Front Seat Belt Lower Anchor 4. Remove the screw that secures the lower seat belt anchor plate to the seat adjuster. 5. Unsnap and remove the front shoulder belt turning loop cover to access the screw that secures the turning loop to the height adjuster. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt and Retractor - Front Seat > Page 6219 Fig.18 Front Shoulder Belt & Refractor - Quad Cab 6. Remove the screw that secures the shoulder belt turning loop to the height adjuster. 7. Remove the shoulder belt turning loop from the height adjuster. 8. Remove the trim from the B-pillar. 9. Remove the two screws that secure the seat belt web guide to the B-pillar above the retractor. 10. Disconnect the seat belt tensioner pigtail wire connector from the body wire harness connector. 11. On the driver side only, disconnect the seat belt switch pigtail wire connector from the body wire harness connector. 12. Remove the screw that secures the retractor to the B-pillar. 13. Remove the front shoulder belt and retractor from the B-pillar. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. 1. Be certain that the retractor shield is properly installed in the B-pillar and in good condition before installing the retractor. 2. Position the retractor into the B-pillar. 3. Install and tighten the screw that secures the retractor to the B-pillar. Tighten the screw to 40 Nm (29 ft. lbs.). 4. Reconnect the seat belt tensioner pigtail wire connector to the body wire harness connector. 5. On the driver side only, reconnect the seat belt switch pigtail wire connector to the body wire harness connector. 6. Position the seat belt web guide to the B-pillar above the retractor. 7. Install and tighten the two screws that secure the seat belt web guide to the B-pillar. Tighten the screws to 2 Nm (17 in. lbs.). 8. Reinstall the trim onto the B-pillar. 9. Position the shoulder belt turning loop onto the height adjuster. 10. Install and tighten the screw that secures the shoulder belt turning loop to the height adjuster. Tighten the screw to 30 Nm (22 ft. lbs.). 11. Snap the trim cover over the front shoulder belt turning loop anchor plate to conceal the screw that secures the turning loop to the height adjuster. 12. Position the lower seat belt anchor plate to the seat adjuster. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt and Retractor - Front Seat > Page 6220 13. Install and tighten the screw that secures the lower seat belt anchor plate to the seat adjuster. Tighten the screw to 30 Nm (22 ft. lbs.). 14. Reposition the cover over the lower seat belt anchor plate to conceal the screw that secures the anchor plate to the front seat adjuster. 15. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt and Retractor - Front Seat > Page 6221 Seat Belt: Service and Repair Seat Belt and Retractor - Second Row REMOVAL WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. 1. Unsnap and remove the second seat shoulder belt turning loop cover to access the screw that secures the turning loop to the height adjuster. Fig. 23 Second Seat Shoulder Belt & Retractor 2. Remove the screw that secures the shoulder belt turning loop to the height adjuster. 3. Remove the shoulder belt turning loop from the height adjuster. 4. Move the trim away from the front of the quarter inner panel and the C-pillar far enough to access the second seat shoulder belt retractor and the lower seat belt anchor plate. 5. Remove the screw that secures the lower seat belt anchor plate to the rear floor panel. 6. Remove the screw that secures the retractor to the C-pillar. 7. Remove the second seat shoulder belt and retractor from the C-pillar. INSTALLATION WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt and Retractor - Front Seat > Page 6222 1. Be certain that the retractor shield is properly installed in the C-pillar and in good condition before installing the retractor. 2. Position the retractor into the C-pillar. 3. Install and tighten the screw that secures the retractor to the C-pillar. Tighten the screw to 40 Nm (29 ft. lbs.). 4. Position the lower seat belt anchor plate to the rear floor panel. 5. Install and tighten the screw that secures the lower seat belt anchor plate to the floor panel. Tighten the screw to 40 Nm (29 ft. lbs.). 6. Reinstall the trim onto the front of the quarter inner panel and the C-pillar. 7. Position the shoulder belt turning loop onto the height adjuster. 8. Install and tighten the screw that secures the shoulder belt turning loop to the height adjuster. Tighten the screw to 40 Nm (29 ft. lbs.). 9. Snap the trim cover over the second seat shoulder belt turning loop anchor plate to conceal the screw that secures the turning loop to the height adjuster. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt and Retractor - Front Seat > Page 6223 Seat Belt: Service and Repair Seat Belt and Retractor - Third Row REMOVAL WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. 1. Unsnap and remove the third seat shoulder belt turning loop cover to access the screw that secures the turning loop to the D-pillar. Fig. 25 Third Seat Shoulder Belt & Retractor 2. Remove the screw that secures the shoulder belt turning loop to the D-pillar. 3. Remove the shoulder belt turning loop from the D-pillar. 4. Remove the nut that secures the third seat lower seat belt anchor plate to the stud on the quarter inner panel. 5. Remove the lower seat belt anchor plate from the stud on the quarter inner panel. 6. Remove the trim from the quarter inner panel. 7. Remove the two screws that secure the seat belt web guide to the D-pillar above the retractor. 8. Remove the screw that secures the retractor to the D-pillar. 9. Remove the third seat shoulder belt and retractor from the D-pillar. INSTALLATION WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt and Retractor - Front Seat > Page 6224 1. Be certain that the retractor shield is properly installed in the D-pillar and in good condition before installing the retractor. 2. Position the retractor into the D-pillar. 3. Install and tighten the screw that secures the retractor to the D-pillar. Tighten the screw to 40 Nm (29 ft. lbs.). 4. Position the seat belt web guide to the D-pillar above the retractor. 5. Install and tighten the two screws that secure the seat belt web guide to the D-pillar. Tighten the screws to 5 Nm (40 in. lbs.). 6. Reinstall the trim onto the quarter inner panel. 7. Position the lower seat belt anchor plate onto the stud on the quarter inner panel. 8. Install and tighten the nut that secures the lower seat belt anchor plate to the stud on the quarter inner panel. Tighten the nut to 40 Nm (29 ft. lbs.). 9. Position the shoulder belt turning loop onto the D-pillar. 10. Install and tighten the screw that secures the shoulder belt turning loop to the D-pillar. Tighten the screw to 40 Nm (29 ft. lbs.). 11. Snap the trim cover over the third seat shoulder belt turning loop anchor plate to conceal the screw that secures the turning loop to the D-pillar. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service Precautions Seat Belt Buckle: Service Precautions WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle - Front Seat Seat Belt Buckle: Service and Repair Seat Belt Buckle - Front Seat REMOVAL WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. 1. If the vehicle is so equipped, remove the console from the floor panel transmission tunnel. 2. If the vehicle is so equipped, remove the center seat from the passenger compartment. Fig. 19 Front Seat Belt Buckle 3. Remove the screw that secures the front seat belt buckle unit to the seat adjuster. 4. Remove the front seat belt buckle from the seat adjuster. INSTALLATION WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. 1. Position the front seat belt buckle to the seat adjuster. 2. Install and tighten the screw that secures the front seat belt buckle unit to the seat adjuster. Tighten the screw to 23 Nm (17 ft. lbs.). The buckle should be free to pivot slightly fore and aft after the screw is tightened. 3. If the vehicle is so equipped, reinstall the center seat into the passenger compartment. 4. If the vehicle is so equipped, reinstall the console onto the floor panel transmission tunnel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle - Front Seat > Page 6230 Seat Belt Buckle: Service and Repair Seat Belt Buckle - Second Row REMOVAL 40/20/40 REAR SEAT WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. 1. Disengage the right or left rear seat latch by pulling upward on the release handle. 2. Fold the right or left rear seat forward against the back of the front seat. Fig. 24 2nd Seat Lap Belt Buckle - 40/20/40 Seat 3. Remove the screw that secures the anchor plate of the rear seat lap belt/buckle unit (left side) or buckle/buckle unit (right side) to the rear floor panel. 4. Remove the rear seat lap belt/buckle unit (left side) or buckle/buckle unit (right side) from the rear floor panel. 60/40 REAR SEAT WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. 1. Remove the rear seat from the rear floor panel. 2. Using a center punch, drive out the mandrel from the center of the rivet securing the anchor plate of the rear seat lap belt/buckle unit (left side) or buckle/buckle unit (right side) to the rear seat cushion rear mounting bracket. 3. Using an appropriately sized drill bit, drill out the rivet that secures the anchor plate of the rear seat lap belt/buckle unit (left side) or buckle/buckle unit (right side) to the rear seat cushion rear mounting bracket. NOTE: The rivets used to secure the anchor plates of the 60/40 rear seat lap belt/buckle unit (left side) and buckle/buckle unit (right side) to the rear seat cushion rear mounting bracket are used as an assembly aid during the manufacturing process. These rivets do not require replacement following service removal of these seat belts. 4. Remove the rear seat lap belt/buckle unit (left side) or buckle/buckle unit (right side) from the rear seat cushion rear mounting bracket. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle - Front Seat > Page 6231 INSTALLATION 40/20/40 REAR SEAT WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. 1. Position the rear seat lap belt/buckle unit (left side) or buckle/buckle unit (right side) onto the rear floor panel. 2. Tinseled and tighten the screw that secures the anchor plate of the rear seat lap belt/buckle unit (left side) or buckle/buckle unit (right side) to the rear floor panel. Tighten the screw to 95 Nm (70 ft. lbs) 3. Return the right or left rear seat to its upright (normal seating) position. 60/40 REAR SEAT WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. NOTE: The rivets used to secure the anchor plates of the 60140 rear seat lap belt/buckle unit (left side) and buckle/buckle unit (right side) to the rear seat cushion rear mounting bracket are used as an assembly aid during the manufacturing process. These rivets do not require replacement following service removal of these seat belts. 1. Reinstall the rear seat onto the rear floor panel, but do not install the screw that secures the removed rear seat lap belt/buckle unit (left side) or buckle/buckle unit (right side) and rear seat cushion rear mounting bracket to the rear floor panel. 2. Position the anchor plate for the rear seat lap belt/buckle unit (left side) or buckle/buckle unit (right side) onto the rear seat cushion rear mounting bracket. 3. Install and tighten the screw that secures the anchor plate of the rear seat lap belt/buckle unit (left side) or buckle/buckle unit (right side) and the rear seat cushion rear mounting bracket to the rear floor panel. Tighten the screw to 95 Nm (70 ft. lbs.). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle - Front Seat > Page 6232 Seat Belt Buckle: Service and Repair Seat Belt Buckle - Third Row REMOVAL WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. 1. Move the third row seat cushion to its cargo position. Fig. 26 3rd Seat Belt Buckle 2. Remove the screw that secures the anchor plate for the third seat belt buckle/buckle unit to the rear floor panel. 3. Remove the third seat belt buckle/buckle unit from the rear floor panel. INSTALLATION WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. 1. Position third seat belt buckle/buckle unit onto the rear floor panel. 2. Install and tighten the screw that secures the anchor plate for the third seat belt buckle/buckle unit to the rear floor panel. Tighten the screw to 40 Nm (29 ft. lbs.). 3. Move the third row seat cushion back to its normal seating position. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations The lumbar control switch paddle is located in a shallow depression molded into the outer surface of the seat cushion side shield that helps to shroud it from unintentional actuation when entering or leaving the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 6236 Seat Belt Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 6237 Seat Belt Buckle Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 6238 Seat Belt Buckle Switch: Description and Operation LUMBAR CONTROL SWITCH The 8-way power seat option includes an electrically operated lumbar support mechanism. A single two-way momentary power lumbar switch is integral with the power seat switches. The power lumbar switch is secured to the back of the seat cushion side shield with screws, and the switch paddle protrudes through a hole to the outside of the shield. The switch paddle is located in a shallow depression molded into the outer surface of the seat cushion side shield that helps to shroud it from unintentional actuation when entering or leaving the vehicle. The power lumbar switches cannot be adjusted or repaired and, if faulty or damaged, the seat switch assembly must be replaced. When the power lumbar switch paddle is actuated, a battery feed and a ground path are applied through the switch contacts to the power lumbar adjuster motor. The motor operates to move the lumbar adjuster through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the motor to run in the opposite direction. The power lumbar switch should not be held applied in either direction after the adjuster has reached its travel limit. The power lumbar adjuster motor contains a self-resetting circuit breaker to protect it from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. SEAT BELT SWITCH The seat belt switch is a small, normally open, single pole, single throw, plunger actuated, momentary switch. Only one seat belt switch is installed in the vehicle, and it is integral to the driver seat belt retractor assembly. The seat belt switch is connected to the vehicle electrical system through a short pigtail wire to a dedicated take out and connector of the body wire harness. The seat belt switch cannot be adjusted or repaired and, if faulty or damaged, the entire driver seat belt and retractor unit must be replaced. The seat belt switch is designed to control a path to ground for the seat belt switch sense input of the Electro-Mechanical Instrument Cluster (EMIC). The seat belt switch plunger is actuated by the seat belt webbing wound onto the seat belt retractor spool. When the seat belt tip-half webbing is pulled out of the retractor far enough to engage the seat belt buckle-half, the switch plunger is extended and closes the seat belt switch sense circuit to ground; and, when the seat belt tip-half webbing is wound onto the retractor the switch plunger is depressed, opening the ground path. The EMIC monitors the seat belt switch status, then controls the seatbelt indicator and sends electronic chime request messages over the Programmable Communications Interface (PCI) data bus to the Central Timer Module (CTM) based upon that input. The seat belt switch receives ground through its pigtail wire connection to the body wire harness from another take out of the body wire harness. An eyelet terminal connector on that ground take out is secured under a ground screw to the left lower B-pillar. The seat belt switch is connected in series between ground and the seat belt switch sense input of the EMIC. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 6239 Seat Belt Buckle Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the seat belt switch from the seat belt switch pigtail wire connector from the driver side front seat belt retractor. Check for continuity between the ground circuit cavity of the body wire harness connector for the seat belt switch and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the open ground circuit to ground (G307) as required. 2. Check for continuity between the two cavities in the seat belt switch pigtail wire connector. There should be no continuity with the seat belt webbing retracted, and continuity with the seat belt webbing pulled out of the retractor far enough to engage the seat belt buckle. If OK, go to Step 3 .If not OK, replace the faulty driver side front seat belt and retractor unit. 3. Remove the instrument cluster from the instrument panel. Check for continuity between the seat belt switch sense circuit cavity of the body wire harness connector for the seat belt switch and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, repair the shorted seat belt switch sense circuit between the seat belt switch and the instrument cluster as required. 4. Check for continuity between the seat belt switch sense circuit cavities of the instrument panel wire harness connector (Connector C2) for the instrument cluster and the body wire harness connector for the seat belt switch. There should be continuity. If OK, proceed to the diagnosis for the instrument cluster. (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). If not OK, repair the open seat belt switch sense circuit between the seat belt switch and the instrument cluster as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 6240 Seat Belt Buckle Switch: Service and Repair REMOVAL The power lumbar switch is integral with the other power seat switches. Refer to the appropriate driver or passenger power front seat switch removal and/or installation procedure. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service Precautions Seat Belt Height Adjuster: Service Precautions WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Seat Belt Turning Loop Adjuster Seat Belt Height Adjuster: Service and Repair Seat Belt Turning Loop Adjuster REMOVAL WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. 1. Remove the knob from the lever of the seat belt turning loop adjuster. (Refer to RESTRAINTS/TURNING LOOP HEIGHT ADJUSTER KNOB REMOVAL). 2. Remove the screw that secures the shoulder belt turning loop to the height adjuster. 3. Remove the trim from the upper B-pillar or C-pillar. 4. Remove the screw that secures the upper end of the height adjuster to the B-pillar or C-pillar. 5. Pull the upper end of the height adjuster away from the B-pillar or C-pillar far enough to disengage the hooks on the lower end of the adjuster from the slots in the pillar. 6. Remove the adjuster from the B-pillar or C-pillar. INSTALLATION WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. 1. Position the height adjuster to the B-pillar or C-pillar with the hook formations oriented toward the lower end of the adjuster. 2. Engage the hooks on the lower end of the adjuster into the slots in the B-pillar or C-pillar. 3. Tilt the upper end of the height adjuster up into position against the B-pillar or C-pillar. 4. Install and tighten the screw that secures the upper end of the height adjuster to the B-pillar or C-pillar. Tighten the screw to 40 Nm (29 ft. lbs.). 5. Reinstall the trim onto the upper B-pillar or C-pillar. 6. Install and tighten the anchor screw that secures the seat belt turning loop to the adjuster. Tighten the screw to 30 Nm (22 ft. lbs.). 7. Reinstall the knob onto the lever of the seat belt turning loop adjuster. (Refer to RESTRAINTS/TURNING LOOP HEIGHT ADJUSTER KNOB INSTALLATION). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Seat Belt Turning Loop Adjuster > Page 6246 Seat Belt Height Adjuster: Service and Repair Seat Belt Turning Loop Height Adjuster Knob REMOVAL WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. 1. Unsnap the seat belt turning loop cover to expose the anchor screw that secures the turning loop to the height adjuster. Fig.14 Shoulder Belt Height Adjuster Knob 2. Using the head of the turning loop anchor screw as a fulcrum, carefully pry the knob from the height adjuster lever with a suitable trim tool. INSTALLATION WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. 1. Snap the seat belt turning loop cover back into place over the anchor screw that secures the turning loop to the adjuster. 2. Position the height adjuster knob to the seat belt turning loop height adjuster lever. 3. Using hand pressure, push the knob firmly and evenly onto the lever until it is fully engaged. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Locations Seat Belt Reminder Lamp: Locations The seatbelt indicator is located in the Information Center area of the instrument cluster, to the right of center. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Locations > Page 6250 Seat Belt Reminder Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Fasten Seat Belts ................................................................................................................................ ................................................................ PC194 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Locations > Page 6251 Seat Belt Reminder Lamp: Description and Operation A seatbelt indicator is standard equipment on all instrument clusters. The seatbelt indicator is located in the Information Center area of the instrument cluster, to the right of center. The seatbelt indicator consists of a stencilled cutout of the International Control and Display Symbol icon for "Seat Belt" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red lens behind the cutout in the opaque layer of the overlay causes the icon to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by a Light Emitting Diode (LED) soldered onto the instrument cluster electronic circuit board. The seatbelt indicator is serviced as a unit with the instrument cluster. The seatbelt indicator gives an indication to the vehicle operator of the status of the driver side front seatbelt. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and a hard wired input from the seatbelt switch in the driver side front seatbelt retractor through the seat belt indicator driver circuit. The seatbelt indicator Light Emitting Diode (LED) receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions; therefore, the indicator will always be OFF when the ignition switch is in any position except ON or Start. The LED only illuminates when it is switched to ground by the instrument cluster transistor. The instrument cluster will turn ON the seatbelt indicator for the following reasons: - Seatbelt Reminder Function - Each time the cluster receives a battery current input on the fused ignition switch output (run-start) circuit, the indicator will be illuminated as a seatbelt reminder for about seven seconds, or until the ignition switch is turned to the OFF position, whichever occurs first. This reminder function will occur regardless of the status of the seatbelt switch input to the cluster. - Driver Side Front Seatbelt Not Buckled - Following the seatbelt reminder function, each time the cluster detects an open circuit on the seat belt indicator driver circuit (seatbelt switch open - seatbelt unbuckled) with the ignition switch in the Start or ON positions, the indicator will be illuminated. The seatbelt indicator remains illuminated until the seat belt indicator driver input to the cluster is closed to ground (seatbelt switch closed - seatbelt buckled), or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The seatbelt switch input to the instrument cluster circuitry can be diagnosed using conventional diagnostic tools and methods. For further diagnosis of the seatbelt indicator or the instrument cluster circuitry that controls the LED, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service Precautions Seat Belt Retractor: Service Precautions WARNING: - ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt Retractor: Service and Repair Front REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. 1. Move the front seats to their most forward position for easiest access to the lower seat belt anchor plate, the retractor, and the B-pillar. 2. Disconnect and isolate the battery negative cable. If either of the airbags has not been deployed, wait two minutes for the system capacitor to discharge before further service. 3. Lift the cover on the lower seat belt anchor plate far enough to access the screw that secures the anchor plate to the front seat adjuster. Fig.17 Front Seat Belt Lower Anchor 4. Remove the screw that secures the lower seat belt anchor plate to the seat adjuster. 5. Unsnap and remove the front shoulder belt turning loop cover to access the screw that secures the turning loop to the height adjuster. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 6257 Fig.18 Front Shoulder Belt & Refractor - Quad Cab 6. Remove the screw that secures the shoulder belt turning loop to the height adjuster. 7. Remove the shoulder belt turning loop from the height adjuster. 8. Remove the trim from the B-pillar. 9. Remove the two screws that secure the seat belt web guide to the B-pillar above the retractor. 10. Disconnect the seat belt tensioner pigtail wire connector from the body wire harness connector. 11. On the driver side only, disconnect the seat belt switch pigtail wire connector from the body wire harness connector. 12. Remove the screw that secures the retractor to the B-pillar. 13. Remove the front shoulder belt and retractor from the B-pillar. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. 1. Be certain that the retractor shield is properly installed in the B-pillar and in good condition before installing the retractor. 2. Position the retractor into the B-pillar. 3. Install and tighten the screw that secures the retractor to the B-pillar. Tighten the screw to 40 Nm (29 ft. lbs.). 4. Reconnect the seat belt tensioner pigtail wire connector to the body wire harness connector. 5. On the driver side only, reconnect the seat belt switch pigtail wire connector to the body wire harness connector. 6. Position the seat belt web guide to the B-pillar above the retractor. 7. Install and tighten the two screws that secure the seat belt web guide to the B-pillar. Tighten the screws to 2 Nm (17 in. lbs.). 8. Reinstall the trim onto the B-pillar. 9. Position the shoulder belt turning loop onto the height adjuster. 10. Install and tighten the screw that secures the shoulder belt turning loop to the height adjuster. Tighten the screw to 30 Nm (22 ft. lbs.). 11. Snap the trim cover over the front shoulder belt turning loop anchor plate to conceal the screw that secures the turning loop to the height adjuster. 12. Position the lower seat belt anchor plate to the seat adjuster. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 6258 13. Install and tighten the screw that secures the lower seat belt anchor plate to the seat adjuster. Tighten the screw to 30 Nm (22 ft. lbs.). 14. Reposition the cover over the lower seat belt anchor plate to conceal the screw that secures the anchor plate to the front seat adjuster. 15. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 6259 Seat Belt Retractor: Service and Repair Second Row REMOVAL WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. 1. Unsnap and remove the second seat shoulder belt turning loop cover to access the screw that secures the turning loop to the height adjuster. Fig. 23 Second Seat Shoulder Belt & Retractor 2. Remove the screw that secures the shoulder belt turning loop to the height adjuster. 3. Remove the shoulder belt turning loop from the height adjuster. 4. Move the trim away from the front of the quarter inner panel and the C-pillar far enough to access the second seat shoulder belt retractor and the lower seat belt anchor plate. 5. Remove the screw that secures the lower seat belt anchor plate to the rear floor panel. 6. Remove the screw that secures the retractor to the C-pillar. 7. Remove the second seat shoulder belt and retractor from the C-pillar. INSTALLATION WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 6260 1. Be certain that the retractor shield is properly installed in the C-pillar and in good condition before installing the retractor. 2. Position the retractor into the C-pillar. 3. Install and tighten the screw that secures the retractor to the C-pillar. Tighten the screw to 40 Nm (29 ft. lbs.). 4. Position the lower seat belt anchor plate to the rear floor panel. 5. Install and tighten the screw that secures the lower seat belt anchor plate to the floor panel. Tighten the screw to 40 Nm (29 ft. lbs.). 6. Reinstall the trim onto the front of the quarter inner panel and the C-pillar. 7. Position the shoulder belt turning loop onto the height adjuster. 8. Install and tighten the screw that secures the shoulder belt turning loop to the height adjuster. Tighten the screw to 40 Nm (29 ft. lbs.). 9. Snap the trim cover over the second seat shoulder belt turning loop anchor plate to conceal the screw that secures the turning loop to the height adjuster. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 6261 Seat Belt Retractor: Service and Repair Third Row REMOVAL WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. 1. Unsnap and remove the third seat shoulder belt turning loop cover to access the screw that secures the turning loop to the D-pillar. Fig. 25 Third Seat Shoulder Belt & Retractor 2. Remove the screw that secures the shoulder belt turning loop to the D-pillar. 3. Remove the shoulder belt turning loop from the D-pillar. 4. Remove the nut that secures the third seat lower seat belt anchor plate to the stud on the quarter inner panel. 5. Remove the lower seat belt anchor plate from the stud on the quarter inner panel. 6. Remove the trim from the quarter inner panel. 7. Remove the two screws that secure the seat belt web guide to the D-pillar above the retractor. 8. Remove the screw that secures the retractor to the D-pillar. 9. Remove the third seat shoulder belt and retractor from the D-pillar. INSTALLATION WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 6262 1. Be certain that the retractor shield is properly installed in the D-pillar and in good condition before installing the retractor. 2. Position the retractor into the D-pillar. 3. Install and tighten the screw that secures the retractor to the D-pillar. Tighten the screw to 40 Nm (29 ft. lbs.). 4. Position the seat belt web guide to the D-pillar above the retractor. 5. Install and tighten the two screws that secure the seat belt web guide to the D-pillar. Tighten the screws to 5 Nm (40 in. lbs.). 6. Reinstall the trim onto the quarter inner panel. 7. Position the lower seat belt anchor plate onto the stud on the quarter inner panel. 8. Install and tighten the nut that secures the lower seat belt anchor plate to the stud on the quarter inner panel. Tighten the nut to 40 Nm (29 ft. lbs.). 9. Position the shoulder belt turning loop onto the D-pillar. 10. Install and tighten the screw that secures the shoulder belt turning loop to the D-pillar. Tighten the screw to 40 Nm (29 ft. lbs.). 11. Snap the trim cover over the third seat shoulder belt turning loop anchor plate to conceal the screw that secures the turning loop to the D-pillar. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations > Page 6266 Seat Belt Tensioner: Diagrams Driver Seat Belt Tensioner Passenger Seat Belt Tensioner Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations > Page 6267 Seat Belt Tensioner: Description and Operation Seat belt tensioners supplement the airbag system for this model. The seat belt tensioners are integral to the front seat belt retractors, which are secured within each B-pillar in the vehicle where they are concealed behind the B-pillar trim. The seat belt tensioner consists primarily of a sprocket/pinion, a steel tube, a cast metal housing, numerous steel balls, a stamped metal ball trap, a torsion bar, a small pyrotechnically activated gas generator, and a short pigtail wire. All of these components are located on one side of the retractor spool on the outside of the retractor housing except for the torsion bar, which serves as the spindle upon which the retractor spool rides. The seat belt tensioners are controlled by the Airbag Control Module (ACM) and are connected to the vehicle electrical system through a dedicated take out of the body wire harness by a keyed and latching molded plastic connector insulator to ensure a secure connection. The seat belt tensioners cannot be repaired and, if faulty or damaged, the entire front seat belt, retractor, and tensioner unit must be replaced. The seat belt tensioners are not intended for reuse, and both tensioners must be replaced following any airbag deployment. A growling or grinding sound while attempting to operate the seat belt retractor is a sure indication that the seat belt tensioner has been deployed and requires replacement. For seat belt tensioner service procedures, (Refer to FRONT SEAT BELT & RETRACTOR - REMOVAL). The seat belt tensioners are deployed in conjunction with the airbags by a signal generated by the Airbag Control Module (ACM) through the driver or passenger seat belt tensioner line 1 and line 2 (or squib) circuits. When the ACM sends the proper electrical signal to the tensioner, the electrical energy generates enough heat to initiate a small pyrotechnic gas generator. The gas generator is installed in one end of a steel tube that contains numerous steel balls. As the gas expands, it pushes the steel balls through the tube into a cast metal housing, where a ball guide directs the balls into engagement with the teeth of a sprocket that is geared to one end of the retractor spool. As the balls drive past the sprocket, the sprocket turns and drives the seat belt retractor spool causing the slack to be removed from the front seat belts. The ball trap captures the balls as they leave the sprocket and are expelled from the housing. Removing excess slack from the front seat belts not only keeps the occupants properly positioned for an airbag deployment following a frontal impact of the vehicle, but also helps to reduce the likelihood of a harmful contact with interior components. Also, the seat belt tensioner torsion bar that the retractor spool rides upon is designed to deform in order to control the loading being applied to the occupants by the seat belts during a frontal impact, further reducing the potential for occupant injuries. The ACM monitors the condition of the seat belt tensioners through circuit resistance, and will illuminate the airbag indicator in the instrument cluster and store a Diagnostic Trouble Code (DTC) for any fault that is detected. For proper diagnosis of the seat belt tensioners, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 6273 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 6274 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 6275 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 6276 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 6277 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 6278 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations The lumbar control switch paddle is located in a shallow depression molded into the outer surface of the seat cushion side shield that helps to shroud it from unintentional actuation when entering or leaving the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 6282 Seat Belt Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 6283 Seat Belt Buckle Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 6284 Seat Belt Buckle Switch: Description and Operation LUMBAR CONTROL SWITCH The 8-way power seat option includes an electrically operated lumbar support mechanism. A single two-way momentary power lumbar switch is integral with the power seat switches. The power lumbar switch is secured to the back of the seat cushion side shield with screws, and the switch paddle protrudes through a hole to the outside of the shield. The switch paddle is located in a shallow depression molded into the outer surface of the seat cushion side shield that helps to shroud it from unintentional actuation when entering or leaving the vehicle. The power lumbar switches cannot be adjusted or repaired and, if faulty or damaged, the seat switch assembly must be replaced. When the power lumbar switch paddle is actuated, a battery feed and a ground path are applied through the switch contacts to the power lumbar adjuster motor. The motor operates to move the lumbar adjuster through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the motor to run in the opposite direction. The power lumbar switch should not be held applied in either direction after the adjuster has reached its travel limit. The power lumbar adjuster motor contains a self-resetting circuit breaker to protect it from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. SEAT BELT SWITCH The seat belt switch is a small, normally open, single pole, single throw, plunger actuated, momentary switch. Only one seat belt switch is installed in the vehicle, and it is integral to the driver seat belt retractor assembly. The seat belt switch is connected to the vehicle electrical system through a short pigtail wire to a dedicated take out and connector of the body wire harness. The seat belt switch cannot be adjusted or repaired and, if faulty or damaged, the entire driver seat belt and retractor unit must be replaced. The seat belt switch is designed to control a path to ground for the seat belt switch sense input of the Electro-Mechanical Instrument Cluster (EMIC). The seat belt switch plunger is actuated by the seat belt webbing wound onto the seat belt retractor spool. When the seat belt tip-half webbing is pulled out of the retractor far enough to engage the seat belt buckle-half, the switch plunger is extended and closes the seat belt switch sense circuit to ground; and, when the seat belt tip-half webbing is wound onto the retractor the switch plunger is depressed, opening the ground path. The EMIC monitors the seat belt switch status, then controls the seatbelt indicator and sends electronic chime request messages over the Programmable Communications Interface (PCI) data bus to the Central Timer Module (CTM) based upon that input. The seat belt switch receives ground through its pigtail wire connection to the body wire harness from another take out of the body wire harness. An eyelet terminal connector on that ground take out is secured under a ground screw to the left lower B-pillar. The seat belt switch is connected in series between ground and the seat belt switch sense input of the EMIC. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 6285 Seat Belt Buckle Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the seat belt switch from the seat belt switch pigtail wire connector from the driver side front seat belt retractor. Check for continuity between the ground circuit cavity of the body wire harness connector for the seat belt switch and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the open ground circuit to ground (G307) as required. 2. Check for continuity between the two cavities in the seat belt switch pigtail wire connector. There should be no continuity with the seat belt webbing retracted, and continuity with the seat belt webbing pulled out of the retractor far enough to engage the seat belt buckle. If OK, go to Step 3 .If not OK, replace the faulty driver side front seat belt and retractor unit. 3. Remove the instrument cluster from the instrument panel. Check for continuity between the seat belt switch sense circuit cavity of the body wire harness connector for the seat belt switch and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, repair the shorted seat belt switch sense circuit between the seat belt switch and the instrument cluster as required. 4. Check for continuity between the seat belt switch sense circuit cavities of the instrument panel wire harness connector (Connector C2) for the instrument cluster and the body wire harness connector for the seat belt switch. There should be continuity. If OK, proceed to the diagnosis for the instrument cluster. (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). If not OK, repair the open seat belt switch sense circuit between the seat belt switch and the instrument cluster as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 6286 Seat Belt Buckle Switch: Service and Repair REMOVAL The power lumbar switch is integral with the other power seat switches. Refer to the appropriate driver or passenger power front seat switch removal and/or installation procedure. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Locations Antenna Cable: Locations The antenna coaxial cable has an additional disconnect, located near the outboard side of the glove box opening on the back side of the lower instrument panel reinforcement. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Locations > Page 6293 Antenna Cable: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL,STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Locations > Page 6294 Antenna Cable: Description and Operation ANTENNA BODY & CABLE All models use a black painted fixed-length stainless steel rod-type antenna mast, installed on the right front fender of the vehicle. The antenna mast has a spiral groove cut down its length to reduce wind noise. The antenna mast is connected to the center wire of the coaxial antenna cable, and is not grounded to any part of the vehicle. To eliminate static, the antenna base must have a good ground. The coaxial antenna cable shield (the outer wire mesh of the cable) is grounded to the antenna base and the radio receiver chassis. The antenna coaxial cable has an additional disconnect, located near the outboard side of the glove box opening on the back side of the lower instrument panel reinforcement. This additional disconnect allows the instrument panel assembly to be removed and installed without removing the radio receiver. The factory-installed Electronically Tuned Radios (ETR) automatically compensate for radio antenna trim. Therefore, no antenna trimmer adjustment is required or possible when replacing the radio receiver or the antenna. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Locations > Page 6295 Antenna Cable: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL,STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. The following four tests are used to diagnose the antenna with an ohmmeter: - Test 1 - Mast to ground test - Test 2 - Tip-of-mast to tip-of-conductor test - Test 3 - Body ground to battery ground test - Test 4 - Body ground to coaxial shield test. Antenna Tests The ohmmeter test lead connections for each test are shown in Antenna Tests. NOTE: - This model has a special coating on the antenna mast which is not electrically conductive. Remove the antenna mast from the antenna base before attempting to perform Tests 1 and 2. - This model has a two-piece antenna coaxial cable. Tests 2 and 4 must be conducted in two steps to isolate a coaxial cable problem; from the coaxial cable connection under the right end of the instrument panel near the outboard side of the glove box opening to the antenna base, and then from the coaxial cable connection to the radio chassis connection. TEST 1 Test 1 determines if the antenna mast is insulated from the base. Proceed as follows: 1. Disconnect the antenna coaxial cable connector from the radio receiver chassis and isolate. Remove the antenna mast from the antenna base. 2. Insert one ohmmeter test lead into the socket for the antenna mast in the center of the antenna base. Connect the other test lead to the perimeter of the antenna base. Check for continuity. 3. There should be no continuity. If continuity is found, replace the faulty or damaged antenna base and cable assembly. TEST 2 Test 2 checks the antenna for an open circuit as follows: 1. Disconnect the antenna coaxial cable connector from the radio receiver chassis. Remove the antenna mast from the antenna base. 2. Insert one ohmmeter test lead into the socket for the antenna mast in the center of the antenna base. Connect the other test lead to the center pin of the antenna coaxial cable connector. 3. Continuity should exist (the ohmmeter should only register a fraction of an ohm). High or infinite resistance indicates damage to the base and cable assembly. Replace the faulty base and cable, if required. TEST 3 Test 3 checks the condition of the vehicle body ground connection. This test should be performed with the battery positive cable removed from the battery. Disconnect both battery cables, the negative cable first. Reconnect the battery negative cable and perform the test as follows: 1. Connect one ohmmeter test lead to the vehicle fender. Connect the other test lead to the battery negative terminal post. 2. The resistance should be less than one ohm. 3. If the resistance is more than one ohm, check the braided ground strap(s) connected to the engine and the vehicle body for being loose, corroded, or damaged. Repair the ground strap connections, if required. TEST 4 Test 4 checks the condition of the ground between the antenna base and the vehicle body as follows: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Locations > Page 6296 1. Connect one ohmmeter test lead to the vehicle fender. Connect the other test lead to the outer crimp on the antenna coaxial cable connector. 2. The resistance should be less then one ohm. 3. If the resistance is more then one ohm, clean and/or tighten the antenna base to fender mounting hardware. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Locations > Page 6297 Antenna Cable: Service and Repair REMOVAL Antenna Body And Cable 1. Disconnect and isolate the battery negative cable. 2. Remove the trim cover from the right cowl side inner panel. 3. Reach under the instrument panel outboard of the glove box to access and disconnect the antenna coaxial cable connector. Disconnect the connector by pulling it apart while twisting the metal connector halves. Do not pull on the cable. 4. Disengage the antenna coaxial cable retainers at the right cowl side inner panel and inside the right front fender. Antenna Mast Remove/Install - Typical 5. Unscrew the antenna mast from the antenna body. Antenna Cap Nut Remove/Install - Typical 6. Remove the antenna cap nut using an antenna nut wrench (Special Tool C-4816), 7. Remove the antenna adapter from the top of the fender. 8. Lower the antenna body through the mounting hole in the top of the fender. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Locations > Page 6298 Antenna Mounting 9. Pull the antenna body and cable out through the opening between the right cowl side outer panel and the fender through the front door opening. 10. Disengage the antenna coaxial cable grommet from the hole in the right cowl side outer panel. 11. Pull the antenna coaxial cable out of the passenger compartment through the hole in the right cowl side outer panel. 12. Remove the antenna body and cable from the vehicle. Instrument Panel Antenna Cable 1. Disconnect and isolate the battery negative cable. 2. React under the instrument panel outboard of the glove box to access and disconnect the antenna coaxial cable connector. Disconnect the connector by pulling it apart while twisting the metal connector halves. Do not pull on the cable. 3. Securely tie a suitable length of cord or twine to the instrument panel half of the antenna coaxial cable connector. This cord will be used to pull or "fish" the cable back into position during installation. 4. Disengage the instrument panel antenna cable from the retainer clips on the glove box opening and instrument panel support. 5. Remove the radio receiver from the instrument panel. (Refer to AUDIO/RADIO - REMOVAL). 6. Pull the antenna cable out through the radio receiver opening in the instrument panel. 7. Untie the cord or twine from the instrument panel antenna cable connector, leaving the cord or twine in place of the cable in the instrument panel. 8. Remove the antenna cable from the instrument panel. INSTALLATION Antenna Body And Cable 1. Position the antenna body and cable in the opening between the right cowl side outer panel and the fender through the front door opening. 2. Push the antenna coaxial cable into the passenger compartment through the hole in the right cowl side outer panel. 3. Engage the antenna coaxial cable grommet in the hole in the right cowl side outer panel. 4. Position the antenna body through the mounting hole in the top of the fender. 5. Install the adapter over the antenna body from the top of the fender. 6. Install and tighten the antenna cap nut using an antenna nut wrench (Special Tool C-4816). Tighten the antenna cap nut to 8 Nm (70 in. lbs.). 7. Install and tighten the antenna mast onto the antenna body. Tighten the mast to 3.3 Nm (30 in. lbs.). 8. Engage the antenna coaxial cable retainers at the right cowl side inner panel and inside the right front fender. 9. Engage the antenna coaxial cable in the retainer clips on the lower instrument panel support and the glovebox. 10. Reach under the instrument panel outboard of the glove box to reconnect the antenna coaxial cable connector. 11. Install the trim cover onto the right cowl side inner panel. 12. Reconnect the battery negative cable. Instrument Panel Antenna Cable 1. Tie the end of the cord or twine that was used during instrument panel antenna cable removal securely to the connector on the end of the antenna coaxial cable being installed into the instrument panel. This cord will be used to pull or "fish" the cable back into position. 2. Using the cord or twine, pull the antenna cable through the radio receiver opening from under the instrument panel. 3. Install the radio receiver onto the instrument panel. (Refer to AUDIO/RADIO - INSTALLATION). 4. Engage the instrument panel antenna cable to the retainer clip on the lower instrument panel support and on the glove box opening. 5. Untie the cord or twine from the instrument panel half of the antenna coaxial cable connector. 6. Reach under the instrument panel outboard of the glove box to access and reconnect the antenna coaxial cable connector. 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Alarm Module: Locations The SKIM is located on the right side of the steering column, below the ignition lock cylinder housing and is concealed beneath the steering column shrouds. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 6303 Alarm Module: Diagrams Sentry Key Immobilizer Module Sentry Key Immobilizer Module Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 6304 Alarm Module: Description and Operation Fig.10 Sentry Key Immobilizer Module SENTRY KEY IMMOBILIZER MODULE The Sentry Key Immobilizer Module (SKIM) is the primary component of the Sentry Key Immobilizer System (SKIS). The SKIM is located on the right side of the steering column, below the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKIM has an integral molded plastic halo-like antenna ring that extends from one end. When the SKIM is properly installed on the steering column, the antenna ring is oriented around the circumference of the ignition lock cylinder housing. A single integral connector receptacle containing six terminal pins is located on the opposite end of the SKIM housing from the antenna ring. A stamped metal mounting bracket secured to the SKIM housing has a U-shaped clip formation that is used to secure the unit to the right lower flange of the steering column jacket. The SKIM cannot be adjusted or repaired. If faulty or damaged, the entire SKIM unit must be replaced. The Sentry Key Immobilizer Module (SKIM) contains a Radio Frequency (RF) transceiver and a microprocessor. The SKIM transmits RF signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring integral to the SKIM housing. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKIM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKIM also communicates over the Programmable Communications Interface (PCI) data bus with the Powertrain Control Module (PCM), the Electro Mechanical Instrument Cluster (EMIC) and/or the DRB III scan tool. The SKIM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKIM. For added system security, each SKIM is programmed with a unique Secret Key code. This code is stored in memory, sent over the PCI data bus to the PCM, and is encoded to the transponder of every Sentry Key that is programmed into the SKIM. Therefore, the Secret Key code is a common element that is found in every component of the Sentry Key Immobilizer System (SKIS). Another security code, called a PIN, is used to gain access to the SKIM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKIM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a PCI data bus message from the PCM during SKIS initialization. In the event that a SKIM replacement is required, the Secret Key code can be transferred to the new SKIM from the PCM using the DRB III® scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKIM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKIM replacement will also require new Sentry Keys. The DRB III scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the ON position, the SKIM transmits an RF signal to the transponder in the ignition key. The SKIM then waits for an RF signal response from the transponder. If the response received identifies the key as valid, the SKIM sends a valid key message to the PCM over the PCI data bus. If the response received identifies the key as invalid, or if no response is received from the key transponder, the SKIM sends an invalid key message to the PCM. The PCM will enable or disable engine operation based upon the status of the SKIM messages. It is important to note that the default condition in the PCM is an invalid key; therefore, if no message is received from the SKIM by the PCM, the engine will be disabled and the vehicle immobilized after two seconds of running. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 6305 The SKIM also sends SKIS indicator status messages to the EMIC over the PCI data bus to tell the EMIC how to operate the SKIS indicator. This indicator status message tells the EMIC to turn the indicator ON for about three seconds each time the ignition switch is turned to the ON position as a bulb test. After completion of the bulb test, the SKIM sends indicator status messages to the EMIC to turn the indicator off, turn the indicator ON, or to flash the indicator ON and OFF. If the SKIS indicator flashes or stays ON solid after the bulb test, it signifies a SKIS fault. If the SKIM detects a system malfunction and/or the SKIS has become inoperative, the SKIS indicator will stay ON solid. If the SKIM detects an invalid key or if a key transponder-related fault exists, the SKIS indicator will flash. If the vehicle is equipped with the Customer Learn transponder programming feature, the SKIM will also send messages to the EMIC to flash the SKIS indicator and to generate a single audible chime tone whenever the Customer Learn programming mode is being utilized. (Refer to VEHICLE THEFT SECURITY - STANDARD PROCEDURE - SENTRY KEY TRANSPONDER PROGRAMMING). The SKIS performs a self-test each time the ignition switch is turned to the ON position, and will store fault information in the form of Diagnostic Trouble Codes (DTC's) in SKIM memory if a system malfunction is detected. The SKIM can be diagnosed, and any stored DTC's can be retrieved using a DRB III scan tool. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 6306 Alarm Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the steering column opening cover from the instrument panel. 3. If the vehicle is so equipped, grasp the tilt steering column knob firmly and pull it straight rearward to remove it from the tilt steering column adjuster mechanism lever located on the left side of the column just below the multi-function switch control stalk. 4. From below the steering column, remove the two outboard screws that secure the upper shroud to the lower shroud. 5. Push gently inward on both sides of the upper shroud near the parting line between the upper and lower shrouds to release the snap features that secure it to the lower shroud. 6. Remove the upper shroud from the lower shroud. 7. From below the steering column, remove the one center screw that secures the lower shroud to the steering column lock housing. 8. Remove the lower shroud from the steering column. Fig.10 Sentry Key Immobilizer Module 9. Disconnect the instrument panel wire harness connector for the Sentry Key Immobilizer Module (SKIM) from the SKIM connector receptacle. 10. Remove the screw that secures the SKIM to the steering column lock housing. 11. Disengage the SKIM antenna ring from around the ignition lock cylinder housing. INSTALLATION 1. Position the Sentry Key Immobilizer Module (SKIM) onto the steering column with the antenna ring oriented around the ignition lock cylinder housing. 2. Install and tighten the screw that secures the SKIM to the steering column lock housing. Tighten the screw to 2 Nm (20 in. lbs.). 3. Reconnect the instrument panel wire harness connector for the SKIM to the SKIM connector receptacle. 4. Position the lower shroud onto the steering column. 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column lock housing. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud onto the steering column. If the vehicle is equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the openings in the right side of the upper and lower shrouds. 7. Align the snap features on the upper shroud with the receptacles on the lower shroud and apply hand pressure to snap them together. 8. From below the steering column, install and tighten the two screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). 9. If the vehicle is so equipped, align the tilt steering column knob with the tilt steering column adjuster mechanism lever located on the left side of the column just below the multi-function switch control stalk and using hand pressure push the knob firmly onto the lever. 10. Reinstall the steering column opening cover onto the instrument panel. 11. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Description and Operation Alarm System Transponder: Description and Operation Sentry Key Immobilizer Transponder TRANSPONDER KEY Each ignition key used in the Sentry Key Immobilizer System (SKIS) has an integral transponder chip. Ignition keys with this feature can be readily identified by a gray rubber cap molded onto the head of the key, while conventional ignition keys have a black molded rubber cap. The transponder chip is concealed beneath the molded rubber cap, where it is molded within a plastic mount into the head of the metal key. In addition to being cut to match the mechanical coding of the ignition lock cylinder, each new Sentry Key has a unique transponder identification code permanently programmed into it by the manufacturer. The Sentry Key transponder cannot be adjusted or repaired. If faulty or damaged, the entire key must be replaced. When the ignition switch is turned to the ON position, the Sentry Key Immobilizer Module (SKIM) communicates through its antenna with the Sentry Key transponder using a Radio Frequency (RF) signal. The SKIM then listens for a RF response from the transponder through the same antenna. The Sentry Key transponder chip is within the range of the SKIM transceiver antenna ring when it is inserted into the ignition lock cylinder. The SKIM determines whether a valid key is present in the ignition lock cylinder based upon the response from the transponder. If a valid key is detected, that fact is communicated by the SKIM to the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus, and the PCM allows the engine to continue running. If the PCM receives an invalid key message, or receives no message from the SKIM over the PCI data bus, the engine will be disabled after about two seconds of operation. The ElectroMechanical Instrument Cluster (EMIC) will also respond to the invalid key message on the PCI data bus by flashing the security indicator ON and OFF. Each Sentry Key has a unique transponder identification code permanently programmed into it by the manufacturer. Likewise, the SKIM has a unique Secret Key code programmed into it by the manufacturer. When a Sentry Key is programmed into the memory of the SKIM, the SKIM stores the transponder identification code from the Sentry Key, and the Sentry Key learns the Secret Key code from the SKIM. Once the Sentry Key learns the Secret Key code of the SKIM, it is permanently stored in the memory of the transponder. Therefore, once a Sentry Key has been programmed to a particular vehicle, it cannot be used on any other vehicle. (Refer to VEHICLE THEFT SECURITY - STANDARD PROCEDURE - TRANSPONDER PROGRAMMING). The SKIS performs a self-test each time the ignition switch is turned to the ON position, and will store key-related fault information in the form of Diagnostic Trouble Codes (DTC's) in SKIM memory if a Sentry Key transponder problem is detected. The Sentry Key transponder chip can be diagnosed, and any stored DTC's can be retrieved using a DRB III scan tool. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Description and Operation > Page 6310 Alarm System Transponder: Service and Repair All Sentry Keys included with the vehicle are preprogrammed to work with the Sentry Key Immobilizer System (SKIS) when it is shipped from the factory. The Sentry Key Immobilizer Module (SKIM) can be programmed to recognize up to a total of eight Sentry Keys. When programming a blank Sentry Key transponder, the key must first be cut to match the ignition switch lock cylinder in the vehicle for which it will be used. Once the additional or new key has been cut, the SKIM must be programmed to recognize it as a valid key. There are two possible methods to program the SKIM to recognize a new or additional valid key, the Secured Access Method and the Customer Learn Method. Following are the details of these two programming methods. Secured Access Method The Secured Access method applies to all vehicles. This method requires the use of a DRB III scan tool. This method will also require that you have access to the unique four-digit PIN code that was assigned to the original SKIM. The PIN code must be used to enter the Secured Access Mode in the SKIM. This PIN number may be obtained from the vehicle owner, from the original vehicle invoice, or from the DaimlerChrysler Customer Center. Refer to the appropriate diagnostic information for the proper Secured Access method programming procedures. Customer Learn Method The Customer Learn feature is only available on domestic vehicles, or those vehicles which have a U.S. country code designator. This programming method also requires access to at least two valid Sentry Keys. If two valid Sentry Keys are not available, or if the vehicle does not have a U.S. country code designator, the Secured Access Method must be used to program new or additional valid keys to the SKIM. The Customer Learn programming method procedures are as follows: 1. Obtain the blank Sentry Key(s) that are to be programmed as valid keys for the vehicle. Cut the blank key(s) to match the ignition switch lock cylinder mechanical key codes. 2. Insert one of the two valid Sentry Keys into the ignition switch and turn the ignition switch to the ON position. 3. After the ignition switch has been in the ON position for longer than three seconds, but no more than fifteen seconds, cycle the ignition switch back to the OFF position. Replace the first valid Sentry Key in the ignition switch lock cylinder with the second valid Sentry Key and turn the ignition switch back to the ON position. The second valid Sentry Key must be inserted in the lock cylinder within fifteen seconds of removing the first valid key. 4. About ten seconds after the completion of Step 3, the security indicator in the instrument cluster will start to flash to indicate that the system has entered the Customer Learn programming mode. 5. Within sixty seconds of entering the Customer Learn programming mode, turn the ignition switch to the OFF position, replace the valid Sentry Key with a blank Sentry Key transponder, and turn the ignition switch back to the ON position. 6. About ten seconds after the completion of Step 5, the security indicator will stop flashing, stay on solid for three seconds, then turn OFF to indicate that the blank Sentry Key has been successfully programmed. The SKIS will immediately exit the Customer Learn programming mode and the vehicle may now be started using the newly programmed valid Sentry Key Each of these steps must be repeated and completed in their entirety for each additional Sentry Key that is to be programmed. If the above steps are not completed in the given sequence, or within the allotted time, the SKIS will exit the Customer Learn programming mode and the programming will be unsuccessful. The SKIS will also automatically exit the Customer Learn programming mode if it sees a non-blank Sentry Key transponder when it should see a blank, if it has already programmed eight (8) valid Sentry Keys, or if the ignition switch is turned to the OFF position for more than about fifty seconds. NOTE: If an attempt is made to start the vehicle while in the Customer Learn mode (security indicator flashing), the SKIS will respond as though the vehicle were being started with an invalid key. In other words, the engine will stall after about two seconds of operation. No faults will be set. - Once a Sentry Key has been programmed as a valid key to a vehicle, it cannot be programmed as a valid key for use on any other vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair Keyless Entry Transmitter Battery: Service and Repair The Remote Keyless Entry (RKE) transmitter case snaps open and shut for battery access. To replace the RKE transmitter batteries: 1. Using a trim stick or a thin coin, gently pry at the notch in the center seam of the RKE transmitter case halves located near the key ring until the two halves unsnap. 2. Lift the back half of the transmitter case off of the RKE transmitter. 3. Remove the two batteries from the RKE transmitter. 4. Replace the two batteries with new Duracell DL2016, or their equivalent. Be certain that the batteries are installed with their polarity correctly oriented. 5. Align the two RKE transmitter case halves with each other, and squeeze them firmly and evenly together using hand pressure until they snap back into place. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Locations > Page 6319 Lock Cylinder Switch: Diagrams Driver Cylinder Lock Switch Liftgate Cylinder Lock Switch Passenger Cylinder Lock Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Locations > Page 6320 Lock Cylinder Switch: Description and Operation DOOR CYLINDER LOCK SWITCH A door cylinder lock switch is snapped onto the back of the key lock cylinder inside each front door. The door cylinder lock switch is a resistor multiplexed momentary switch that is hard wired in series between a body ground and the Central Timer Module (CTM) through the front door wire harness. The door cylinder lock switches are driven by the key lock cylinders and contain three internal resistors. One resistor is used for the neutral switch position, one for the Lock position, and one for the Unlock position. The door cylinder lock switches cannot be adjusted or repaired and, if faulty or damaged, they must be replaced. The door cylinder lock switches are actuated by the key lock cylinder when the key is inserted in the lock cylinder and turned to the lock or unlock positions. The door cylinder lock switch closes a path to ground through one of three internal resistors for the Central Timer Module (CTM) when the front door key lock cylinder is in the Lock, Unlock, or Neutral positions. The CTM reads the switch status through an internal pull-up, then uses this information as an input for both power lock system and Vehicle Theft Security System (VTSS) operation. The door cylinder lock switches and circuits can be diagnosed using conventional diagnostic tools and methods. LIFTGATE CYLINDER LOCK SWITCH The liftgate cylinder lock switch is snapped onto the back of the liftgate key lock cylinder inside the liftgate. The liftgate cylinder lock switch is a resistor multiplexed momentary switch that is hard wired in series between a body ground and the Central Timer Module (CTM) through the liftgate wire harness. The liftgate cylinder lock switch is driven by the key lock cylinder and contains three internal resistors. One resistor is used for the neutral switch position, one for the Lock position and one for the Unlock position. The liftgate cylinder lock switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The liftgate cylinder lock switch is actuated by the key lock cylinder when the key is inserted in the lock cylinder and turned to the lock or unlock positions. The liftgate cylinder lock switch closes a path to ground through one of three internal resistors for the Central Timer Module (CTM) when the liftgate key lock cylinder is in the Lock, Unlock, or Neutral positions. The CTM reads the switch status through an internal pull-up, then uses this information as an input for both the power lock system and Vehicle Theft Security System (VTSS) operation. The liftgate cylinder lock switch and circuits can be diagnosed using conventional diagnostic tools and methods. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Testing and Inspection > Door Cylinder Lock Switch Test Lock Cylinder Switch: Testing and Inspection Door Cylinder Lock Switch Test 1. Disconnect the door cylinder lock switch pigtail wire connector from the door wire harness connector. DOOR LOCK CYLINDER SWITCH 2. Using an ohmmeter, perform the switch resistance checks between the two cavities of the door cylinder lock switch pigtail wire connector. Actuate the switch by rotating the key in the door lock cylinder to test for the proper resistance values in each of the three switch positions, as shown in the Door Cylinder Lock Switch chart. 3. If a door cylinder lock switch fails any of the resistance tests, replace the faulty switch as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Testing and Inspection > Door Cylinder Lock Switch Test > Page 6323 Lock Cylinder Switch: Testing and Inspection Liftgate Cylinder Lock Switch Test 1. Disconnect the liftgate cylinder lock switch pigtail wire connector from the liftgate wire harness connector. Liftgate Cylinder Lock Switch 2. Using an ohmmeter, perform the switch resistance checks between the two cavities of the liftgate cylinder lock switch pigtail wire connector. Actuate the switch by rotating the key in the liftgate lock cylinder to test for the proper resistance values in each of the three switch positions, as shown in the Liftgate Cylinder Lock Switch chart. 3. If a liftgate cylinder lock switch fails any of the resistance tests, replace the faulty switch as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Service and Repair > Door Cylinder Lock Switch Replacement Lock Cylinder Switch: Service and Repair Door Cylinder Lock Switch Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door outside latch handle mounting hardware and linkage from the inside of the door. Door Lock Cylinder Switch Remove/Install - Typical 3. From the outside of the door, pull the door outside latch handle out from the door far enough to access the door cylinder lock switch. 4. Disengage the door cylinder lock switch from the back of the lock cylinder. 5. Disconnect the door cylinder lock switch pigtail wire connector from the door wire harness connector. 6. Disengage the retainers that secure the door cylinder lock switch pigtail wire harness to the inner door panel. 7. Remove the door cylinder lock switch from the door. INSTALLATION 1. Position the door cylinder lock switch into the door. 2. Engage the retainers that secure the door cylinder lock switch pigtail wire harness to the inner door panel. 3. Reconnect the door cylinder lock switch pigtail wire connector to the door wire harness connector. 4. Reinstall the door cylinder lock switch onto the back of the lock cylinder. 5. Reinstall the door outside latch handle mounting hardware and linkage on the inside of the door. 6. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Service and Repair > Door Cylinder Lock Switch Replacement > Page 6326 Lock Cylinder Switch: Service and Repair Liftgate Cylinder Lock Switch Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the liftgate inner panel. Liftgate Lock Cylinder Switch Remove/Install 3. Reach through the access hole in the liftgate inner panel to access and disengage the liftgate cylinder lock switch from the back of the lock cylinder. 4. Disconnect the liftgate cylinder lock switch pigtail wire connector from the liftgate wire harness connector. 5. Disengage the retainers that secure the liftgate cylinder lock switch pigtail wire harness to the liftgate inner panel. 6. Remove the liftgate cylinder lock switch from the liftgate. INSTALLATION 1. Position the liftgate cylinder lock switch into the liftgate. 2. Engage the retainers that secure the liftgate cylinder lock switch pigtail wire harness to the liftgate inner panel. 3. Reconnect the liftgate cylinder lock switch pigtail wire connector to the liftgate wire harness connector. 4. Reinstall the trim panel onto the liftgate inner panel. 5. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Locations Security Lamp/Indicator: Locations The security indicator is located in the Information Center area of the instrument cluster, to the left of center. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Locations > Page 6330 Security Lamp/Indicator: Description and Operation A security indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional Vehicle Theft Security System (VTSS), this indicator is mechanically disabled. The security indicator is located in the Information Center area of the instrument cluster, to the left of center. The security indicator consists of a stenciled cutout of the word "SECURITY" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red lens behind the cutout in the opaque layer of the overlay causes the "SECURITY" text to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by a Light Emitting Diode (LED) soldered onto the instrument cluster electronic circuit board. The security indicator is serviced as a unit with the instrument cluster. The security indicator gives an indication to the vehicle operator when the Vehicle Theft Security System (VTSS) is arming or is armed. On models equipped with the Sentry Key Immobilizer System (SKIS), the security indicator also gives an indication to the vehicle operator of the status of the SKIS. This indicator is controlled by a hard wired input to the instrument cluster from the Central Timer Module (CTM) on the VTSS indicator driver circuit and, if the vehicle is so equipped, by a transistor on the instrument cluster circuit board based upon electronic messages received by the cluster from the Sentry Key Immobilizer Module (SKIM) over the Programmable Communications Interface (PCI) data bus. The security indicator Light Emitting Diode (LED) receives battery current on the instrument cluster electronic circuit board at all times through the fused B(+) circuit at all times; therefore, the LED will remain functional regardless of the ignition switch position. The LED only illuminates when it is provided a path to ground by the CTM or by the instrument cluster transistor. The security indicator will be illuminated for the following reasons: - Bulb Test - If the vehicle is equipped with SKIS, each time the ignition switch is turned to the ON position the security indicator is illuminated by the instrument cluster for about three seconds based upon an electronic lamp-ON message received from the SKIM as a bulb test. There is no bulb test performed for models that are not equipped with the optional SKIS. - VTSS Indication - During the seventeen second VTSS arming function, the CTM will flash the security indicator ON and OFF repeatedly at a steady, fast rate to indicate that the VTSS is in the process of arming. Following successful VTSS arming, the CTM flashes the security indicator ON and OFF continuously at a slower rate to indicate that the VTSS is armed. The security indicator continues flashing at the slower rate until the VTSS is disarmed or triggered. If the VTSS alarm is triggered, the CTM will flash the security indicator at a steady, fast rate for up to eighteen minutes or until the triggering condition is removed, before returning to the slower, armed flash rate. - SKIM Lamp-ON Message - Each time the cluster receives a lamp-on message from the SKIM, the security indicator will be illuminated. The indicator can be flashed ON and OFF, or illuminated solid, as dictated by the SKIM message. The indicator remains illuminated solid or continues to flash until the cluster receives a lamp-OFF message from the SKIM, or until the ignition switch is turned to the OFF position, whichever occurs first. For more information on the SKIS and the security indicator control parameters, (Refer to VEHICLE THEFT SECURITY/SENTRY KEY IMMOBILIZER SYSTEM - OPERATION). - Actuator Test - Each time the instrument cluster is put through the actuator test, the security indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The CTM provides a hard wired ground input to the instrument cluster circuitry through the VTSS indicator driver circuit whenever the ignition switch is in the OFF position and the VTSS is arming, armed, or triggered. Whenever the ignition switch is in the ON or Start positions, the SKIM performs a self-test to decide whether the system is in good operating condition. The SKIM then sends the proper lamp-ON or lamp-OFF messages to the instrument cluster. For further diagnosis of the security indicator or the instrument cluster circuitry that controls the indicator, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). If the SKIS turns ON the security indicator after the bulb test, either solid or flashing, it indicates that a SKIS malfunction has occurred or that the SKIS is inoperative. The VTSS indicator driver circuit input to the instrument cluster can be diagnosed using conventional diagnostic tools and methods. For proper diagnosis of the VTSS, the CTM, the SKIS, the PCI data bus, or the message inputs to the instrument cluster that control the security indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Customer Interest for Driver/Vehicle Information Display: > 08-006-01 > Mar > 01 > Overhead Console Display - Inaccurate MPG Reading Driver/Vehicle Information Display: Customer Interest Overhead Console Display - Inaccurate MPG Reading NUMBER: 08-006-01 GROUP: Electrical DATE: Mar. 23, 2001 SUBJECT: Inaccurate Miles Per Gallon/Distance To Empty Reading From Overhead Console OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration level 01Cal14) MODELS: 2001 (AN) Dakota 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 4.7L ENGINE. SYMPTOM/CONDITION: The vehicle's overhead console may display a Miles Per Gallon (MPG) that is approximately two MPG higher than what the vehicle actually is getting. Additionally, one of the inputs for the Distance To Empty (DTE) reading is taken from the MPG reading which may cause the DTE reading to be inaccurate. DIAGNOSIS/REPAIR PROCEDURES: Due to the nature of this issue, perform the Repair Procedure on any subject model vehicle in which the customer complains that the vehicle is getting approximately two miles per gallon less than displayed on the overhead console. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRBIII(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR, WHEN USING THE MDS2 AND THE DRBIII(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2077 OR HIGHER. REPAIR PROCEDURE: 1. Reprogram the PCM using the MDS2 (Mopar Diagnostic System) and the DRB III(R) (Scan Tool). NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, 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 WITH A MODULE. 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 ERASED. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Customer Interest for Driver/Vehicle Information Display: > 08-006-01 > Mar > 01 > Overhead Console Display - Inaccurate MPG Reading > Page 6339 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 PCM 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Driver/Vehicle Information Display: > 08-006-01 > Mar > 01 > Overhead Console Display - Inaccurate MPG Reading Driver/Vehicle Information Display: All Technical Service Bulletins Overhead Console Display Inaccurate MPG Reading NUMBER: 08-006-01 GROUP: Electrical DATE: Mar. 23, 2001 SUBJECT: Inaccurate Miles Per Gallon/Distance To Empty Reading From Overhead Console OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration level 01Cal14) MODELS: 2001 (AN) Dakota 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 4.7L ENGINE. SYMPTOM/CONDITION: The vehicle's overhead console may display a Miles Per Gallon (MPG) that is approximately two MPG higher than what the vehicle actually is getting. Additionally, one of the inputs for the Distance To Empty (DTE) reading is taken from the MPG reading which may cause the DTE reading to be inaccurate. DIAGNOSIS/REPAIR PROCEDURES: Due to the nature of this issue, perform the Repair Procedure on any subject model vehicle in which the customer complains that the vehicle is getting approximately two miles per gallon less than displayed on the overhead console. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRBIII(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR, WHEN USING THE MDS2 AND THE DRBIII(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2077 OR HIGHER. REPAIR PROCEDURE: 1. Reprogram the PCM using the MDS2 (Mopar Diagnostic System) and the DRB III(R) (Scan Tool). NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, 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 WITH A MODULE. 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 ERASED. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Driver/Vehicle Information Display: > 08-006-01 > Mar > 01 > Overhead Console Display - Inaccurate MPG Reading > Page 6345 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 PCM 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Page 6346 Driver/Vehicle Information Display: Description and Operation OVERHEAD CONSOLE An overhead console unit is an available factory-installed option on this model The overhead console unit features a garage door opener storage bin, a sunglasses storage bin, two reading and courtesy lamps and either a standard paperclip or an optional compass mini-trip computer. See the owner's manual in the vehicle glove box for more information on the features, use and operation of all of the overhead console components and systems. The overhead console for this model includes two front-mounted reading and courtesy lamps, a sunglasses storage bin, universal transmitter and either a standard paperclip or an optional compass mini-trip computer. The overhead console is secured with two snap clips at the rear and a single screw at the front to the overhead console mounting bracket. The front of the overhead console mounting bracket is secured to the roof header near the windshield with two screws, and the rear of the bracket is secured with double-faced tape to the inside surface of the roof panel. A single electrical connection joins the overhead console wire harness to the roof wire harness. Following are general descriptions of the major components used in the overhead console. See the owner's manual in the vehicle glove box for more information on the use and operation of the various overhead console features. Sunglass Storage Bin A sunglasses storage bin is included in the overhead console. The storage bin is located near the center of the overhead console and is held in the closed position by a spring-loaded latch mechanism that is integral to the storage bin door. The interior of the bin is lined with a foam rubber padding material to protect the sunglasses from being scratched. A damper spring is snapped onto the pivot shaft of the sunglasses storage bin door. The damper spring engages two flats on the shaft and is anchored in a slot in the rear flange of the overhead console reading and courtesy lamp housing to provide a smooth opening action and an open detent position for the storage bin unit. The sunglasses storage bin and door unit is available for service replacement. The bin and door unit includes the spring-loaded latch mechanism, the bin liner and the damper spring. If any of these components is damaged or faulty, the sunglasses storage bin and door unit must be replaced. The sunglasses storage bin is opened by pressing the latch on the rear edge of the door towards the front of the vehicle, then pulling the bin downward to the open detent position. The spring4oaded latch mechanism on the sunglasses bin door will automatically engage when the bin is closed. See the owner's manual in the vehicle glove box for more information on the use and operation of the sunglasses storage bin. Paperclip A paperclip is standard equipment on the base version of the overhead console. The paperclip provides a convenient place for storage and easy retrieval of notes, maps, toll tickets or stubs and other paper items that may be required or desired while driving. The paperclip is located near the front of the overhead console and is secured in the overhead console housing by four screws. The paperclip is available for service replacement, but it cannot be adjusted or repaired. If the paperclip is damaged or faulty it must be replaced. COMPASS/MINI-TRIP COMPUTER The compass mini-trip computer is located in the overhead console on models equipped with this option. The compass mini-trip computer units include the electronic control module, a Vacuum-Fluorescent Display (VFD), a compass sensor unit and two push button function switches. The compass mini-trip computer module contains a central processing unit and interfaces with other electronic modules in the vehicle on the Programmable Communication Interface (J1850) data bus network. The J1850 data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. The compass mini-trip computer provides several electronic functions and features. Some of the functions and features that the compass mini-trip computer module supports and/or controls, include the following display options: Compass and temperature - provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. - Trip Odometer (TRIP ODO) - shows the distance travelled since the last trip computer reset. - Average fuel economy (AVG ECO) - shows the average fuel economy since the last trip computer reset. - Instant fuel economy (ECO) - shows the present fuel economy based upon the current vehicle distance and fuel used information. - Distance To Empty (DTE) - shows the estimated distance that can be travelled with the fuel remaining in the fuel tank. This estimated distance is computed using the average miles-per-gallon from the last 30 gallons of fuel used. - Elapsed Time (ET) - shows the accumulated ignition-on time since the last trip computer reset. - Blank screen - the compass mini-trip VFD is turned OFF. The ambient temperature sensor is hard wired to the IWAC control head. Data input for all other compass mini-trip computer functions, including VFD dimming level, is received through J1850 data bus messages. The compass mini-trip computer uses its internal programming and all of these inputs to calculate and display the requested data. If the data displayed is incorrect, perform the self-diagnostic tests. If these tests prove inconclusive, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended for further testing of the compass mini-trip computer module and the J1850 data bus. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Page 6347 The compass mini-trip computer module cannot be repaired, and is available for service only as a unit. This unit includes the push button switches and the plastic module and display lens. If any of these components is faulty or damaged, the complete compass mini-trip computer module must be replaced. Compass While in the compass/temperature mode, the compass will display the direction in which the vehicle is pointed using the eight major compass headings (Examples: north is N, northeast is NE). The self-calibrating compass unit requires no adjusting in normal use. The only calibration that may prove necessary is to drive the vehicle in three complete circles, on level ground, in not less than forty-eight seconds. This will reorient the compass unit to its vehicle. The compass unit also will compensate for magnetism the body of the vehicle may acquire during normal use. However, avoid placing anything magnetic directly on the roof of the vehicle. Magnetic mounts for an antenna, a repair order hat, or a funeral procession flag can exceed the compensating ability of the compass unit if placed on the roof panel. Magnetic bit drivers used on the fasteners that hold the overhead console assembly to the roof header can also affect compass operation. If the vehicle roof should become magnetized, the demagnetizing and calibration procedures found may be required to restore proper compass operation. The compass mini-trip computer only operates with the ignition switch in the ON position. When the ignition switch is turned to the ON position, all of the segments in the compass mini-trip computer VFD will be turned OFF for one second, then the display will return to the last function being displayed before the ignition was turned to the OFF position. With the ignition switch in the ON position, momentarily depressing and releasing the Step push button switch will cause the compass-mini-trip computer to change its mode of operation, and momentarily depressing and releasing the U.S./Metric push button will cause the unit to toggle between U.S. and Metric measurements. This compass mini-trip computer features several functions that can be reset. If both the Step and U.S/Metric push buttons are depressed at the same time for more than one second with the ignition switch in the On position, the trip computer information that can be reset is reset. However, the reset will only occur if the function currently displayed is a function that can be reset. The functions that can be reset are: TRIP ODO, AVG ECO, and ET. For more information on the features and control functions of the compass mini-trip computer, see the owner's manual in the vehicle glove box. Thermometer The thermometer displays the outside ambient temperature in whole degrees. The temperature display can be changed from Fahrenheit to Celsius using the U.S./Metric push button. The displayed temperature is not an instant reading of conditions, but an average temperature. It may take the thermometer display several minutes to respond to a major temperature change, such as driving out of a heated garage into winter temperatures. When the ignition switch is turned to the OFF position, the last displayed temperature reading stays in the thermometer unit memory. When the ignition switch is turned to the ON position again, the thermometer will display the memory temperature if the engine coolant temperature is above about 52 °C (125 °F). If the engine coolant temperature is below about 52 °C (125 °F), the thermometer will display the actual temperature sensed by the ambient temperature sensor. The thermometer temperature display update interval varies with the vehicle speed. The thermometer function is supported by an ambient temperature sensor. The sensor is mounted outside the passenger compartment near the front and center of the vehicle, and is hard wired to the HVAC control head which sends temperature on J1850 data bus circuit. The ambient temperature sensor is available as a separate service item. NOTE: The compass mini-trip computer will display "OC" for temperatures below -40 °C and "SC" for temperatures above 55 °C. AMBIENT TEMPERATURE SENSOR Ambient air temperature is monitored by the compass mini-trip computer module through the ambient temperature sensor. The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the right side of the radiator yoke, behind the radiator grille and in front of the engine compartment. For complete circuit diagrams, refer to Overhead Console in the Contents of Wiring Diagrams. The ambient temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent to it by the compass mini-trip computer module. The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the compass mini-trip computer module. Based upon the resistance in the sensor, the compass mini-trip computer module senses a specific voltage on the temperature sensor signal circuit, which it is programmed to correspond to a specific temperature. UNIVERSAL TRANSMITTER On some models a Universal Garage Door Opener (UGDO) transceiver is standard factory-installed equipment. The UGDO transceiver is integral to the overhead console. The only visible component of the UGDO are the three transmitter push buttons at the rear of the overhead console. The three UGDO transmitter push buttons are identified with one, two or three raised tactile bumps so that they be easily identified by sight or by feel. Each of the three UGDO transmitter push buttons controls an independent radio transmitter channel. Each of these three channels can be trained to transmit a different radio frequency signal for the remote operation of garage door openers, motorized gate openers, home or Office lighting, security systems or just about any other device that can be equipped with a radio receiver in the 286 to 399 MegaHertz (MHz) frequency range for remote operation. The UGDO is capable of operating systems using either rolling code or non-rolling code technology. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Page 6348 The UGDO cannot be repaired, and is available for service only as a unit. This unit includes the push button switches and the plastic module. The UGDO operates on a non-switched source of battery current so the unit will remain functional, regardless of the ignition switch position. For more information on the features, programming procedures and operation of the UGDO, see the owner's manual in the vehicle glove box. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Description and Operation Garage Door Opener Transmitter: Description and Operation UNIVERSAL TRANSMITTER On some models a Universal Garage Door Opener (UGDO) transceiver is standard factory-installed equipment. The UGDO transceiver is integral to the overhead console. The only visible component of the UGDO are the three transmitter push buttons at the rear of the overhead console. The three UGDO transmitter push buttons are identified with one, two or three raised tactile bumps so that they be easily identified by sight or by feel. Each of the three UGDO transmitter push buttons controls an independent radio transmitter channel. Each of these three channels can be trained to transmit a different radio frequency signal for the remote operation of garage door openers, motorized gate openers, home or office lighting, security systems or just about any other device that can be equipped with a radio receiver in the 286 to 399 MegaHertz (MHz) frequency range for remote operation. The UGDO is capable of operating systems using either rolling code or non-rolling code technology. The UGDO cannot be repaired, and is available for service only as a unit. This unit includes the push button switches and the plastic module. The UGDO operates on a non-switched source of battery current so the unit will remain functional, regardless of the ignition switch position. For more information on the features, programming procedures and operation of the UGDO, see the owner's manual in the vehicle glove box. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Erasing Transmitter Codes Garage Door Opener Transmitter: Service and Repair Erasing Transmitter Codes Fig. 7 Universal Transmitter To erase the universal transmitter codes simply hold down the two outside buttons until the red LED begins to flash. NOTE: individual channels cannot be erased. Erasing the transmitter codes will erase ALL programmed codes. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Erasing Transmitter Codes > Page 6354 Garage Door Opener Transmitter: Service and Repair Setting Transmitter Codes 1. Turn OFF the engine. 2. Erase the factory test codes by pressing the two outside buttons. Release the buttons when the red light begins to flash (about 20 seconds). 3. Choose one of the three buttons to train. Place the hand-held transmitter within one inch of the universal transmitter and push the buttons on both transmitters. The red light on the universal transmitter will begin to flash slowly. 4. When the red light on the universal transmitter begins to flash rapidly (this may take as long as 60 seconds), release both buttons. Your universal transmitter is now "trained". To train the other buttons, repeat Step 3 and Step 4. Be sure to keep your hand-held transmitter in case you need to retrain the universal transmitter. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Erasing Transmitter Codes > Page 6355 Garage Door Opener Transmitter: Service and Repair Universal Transmitter Replacement REMOVAL 1. Remove the overhead console from the vehicle. 2. Remove the transmitter retaining screws. 3. Disconnect harness connector from Universal Transmitter and remove from the overhead console. INSTALLATION 1. Connect harness connector on Universal Transmitter and install in the overhead console. 2. Install the transmitter retaining screws. 3. Install the overhead console in the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams Amplifier: Diagrams Amplifier C1 Amplifier C2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 6360 Amplifier: Description and Operation Models equipped with the Infinity premium speaker package have a separate power amplifier unit. This power amplifier is rated at 120 watts output. The power amplifier unit is mounted to the right cowl side inner panel under the passenger side end of the instrument panel. The power amplifier unit can be accessed for service by removing the trim from the right cowl side inner panel. The power amplifier unit should be checked if there is no sound output noted from the speakers. For diagnosis of the power amplifier, (Refer to SPEAKER - DIAGNOSIS AND TESTING). The power amplifier cannot be repaired or adjusted and, if faulty or damaged, the unit must be replaced. The power amplifier receives fused battery current from a fuse in the Junction Block (JB) at all times. The internal circuitry of the power amplifier switches the amplifier on based upon a fused 12 volt output signal that is received from the radio receiver whenever the radio is turned ON. The power amplifier receives the sound signal inputs for four speaker channels from the radio receiver, then sends the amplified speaker outputs for each of those channels to the eight speakers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 6361 Amplifier: Testing and Inspection The amplifier unit should be checked if there is no sound output noted from the speakers. For diagnosis of the power amplifier, (Refer to SPEAKER - DIAGNOSIS AND TESTING). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 6362 Amplifier: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the trim cover from the right cowl side inner panel. 3. Disconnect the two instrument panel wire harness connectors from the connector receptacles on the bottom of the power amplifier. 4. Remove the three screws that secure the power amplifier to the right cowl side inner panel. 5. Remove the power amplifier from the right cowl side inner panel. INSTALLATION 1. Position the power amplifier to the right cowl side inner panel. 2. Install the three screws that secure the power amplifier to the right cowl side inner panel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Reconnect the two instrument panel wire harness connectors to the connector receptacles on the bottom of the power amplifier. 4. Install the trim cover onto the right cowl side inner panel. 5. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service Precautions Radio/Stereo Noise Filter: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service Precautions > Page 6367 Radio/Stereo Noise Filter: Description and Operation RADIO NOISE SUPPRESSION GROUND STRAP Radio Frequency Interference (RFI) and ElectroMagnetic Interference (EMI) noise suppression is accomplished primarily through circuitry internal to the radio receivers. These internal suppression devices are only serviced as part of the radio receiver. External suppression devices that are used on this vehicle to control RFI or EMI noise include the following: Radio antenna base ground - Radio receiver chassis ground wire or strap - Engine-to-body ground strap(s) - Exhaust system-to-body ground strap (this engine only) - Resistor-type spark plugs - Radio suppression-type secondary ignition wiring. For more information on the spark plugs and secondary ignition components, (Refer to IGNITION COIL - DESCRIPTION). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service Precautions > Page 6368 Radio/Stereo Noise Filter: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Inspect the ground paths and connections at the following locations: - Blower motor - Electric fuel pump - Engine-to-body ground strap(s) - Generator - Ignition module - Radio antenna base ground - Radio receiver chassis ground wire or strap - Wiper motor. If the source of RFI or EMI noise is identified as a component on the vehicle (i.e., generator, blower motor, etc.), the ground path for that component should be checked. If excessive resistance is found in any ground circuit, clean, tighten, or repair the ground circuits or connections to ground as required before considering any component replacement. For service and inspection of secondary ignition components, refer to IGNITION CONTROLS. Inspect the following secondary ignition system components: - Distributor cap and rotor - Ignition coil - Spark plugs - Spark plug wire routing and condition. Reroute the spark plug wires or replace the faulty components as required. If the source of the RFI or EMI noise is identified as two-way mobile radio or telephone equipment, check the equipment installation for the following: - Power connections should be made directly to the battery, and fused as closely to the battery as possible. - The antenna should be mounted on the roof or toward the rear of the vehicle. Remember that magnetic antenna mounts on the roof panel can adversely affect the operation of an overhead console compass, if the vehicle is so equipped. - The antenna cable should be fully shielded coaxial cable, should be as short as is practical, and should be routed away from the factory-installed vehicle wire harnesses whenever possible. - The antenna and cable must be carefully matched to ensure a low Standing Wave Ratio (SWR). Fleet vehicles are available with an extra-cost RFI suppressed Powertrain Control Module (PCM). This unit reduces interference generated by the PCM on some radio frequencies used in two-way radio communications. However, this unit will not resolve complaints of RFI in the commercial AM or FM radio frequency ranges. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service Precautions > Page 6369 Radio/Stereo Noise Filter: Service and Repair REMOVAL ENGINE-TO-BODY GROUND STRAPS Fig. 7 Engine-To-Body Ground Strap Remove/Install - Typical 1. Remove the nut and washer that secures the left engine-to-body ground strap eyelet terminal to the weld stud on the left side of the lower plenum panel. 2. Remove the nut and washer that secures the right engine-to-body ground strap eyelet terminal to the inboard weld stud on the right side of the lower plenum panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service Precautions > Page 6370 Fig. 8 Engine-To-Body Ground Strap Remove/Install 3. Remove the screw that secures the left engine-to-body ground strap eyelet terminal to the rear of the left cylinder head. 4. Remove the screw that secures the right engine-to-body ground strap eyelet terminal to the rear of the right cylinder head. Fig. 10 Engine-To Body Ground Strap Remove/Install 5. On this engine only, remove the nut and washer that secures the right engine-to-body ground strap eyelet terminal and the wire harness grounds to the weld stud on the right front fender wheelhouse inner panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service Precautions > Page 6371 Fig. 11 Engine-To-Body Ground Strap Remove/Install 6. On this engine only, remove the screw and washer that secures the right engine-to-body ground strap eyelet terminal to the transmission at the right rear corner of the engine block. 7. Remove the engine-to-body ground strap(s) from the engine compartment. EXHAUST SYSTEM-TO-BODY GROUND STRAP 1. Raise and support the vehicle. Fig. 12 Exhaust System-To-Body Ground Strap Remove/Install Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service Precautions > Page 6372 2. Remove the nut and washer that secures the exhaust system-to-body ground strap eyelet terminal to the exhaust pipe clamp. 3. Remove the screw that secures the exhaust system-to-body ground strap eyelet terminal to the right body sill panel. 4. Remove the exhaust system-to-body ground strap from over the top of the right frame rail. INSTALLATION ENGINE-TO-BODY GROUND STRAPS 1. Position the engine-to-body ground strap(s) in the engine compartment. 2. On this engine only, install and tighten the screw and washer that secures the right engine-to-body ground strap eyelet terminal to the transmission at the right rear corner of the engine block. Tighten the screw to 67.8 Nm (50 ft. lbs.). 3. On this engine only, position the right engine-to-body ground strap eyelet terminal and the wire harness grounds over the weld stud on the right front fender wheelhouse inner panel. 4. On this engine only, install and tighten the nut and washer that secures the right engine-to-body ground strap eyelet terminal and the wire harness grounds to the weld stud on the right front fender wheelhouse inner panel. Tighten the nut to 11.8 Nm (105 in. lbs.). 5. Install and tighten the screw that secures the right engine-to-body ground strap eyelet terminal to the rear of the right cylinder head. On this engine, tighten the screw to 10.7 Nm (95 in. lbs.). 6. Install and tighten the screw that secures the left engine-to-body ground strap eyelet terminal to the rear of the left cylinder head. On this engine, tighten the screw to 10.7 Nm (95 in. lbs.). 7. Position the right engine-to-body ground strap eyelet over the inboard weld stud on the right side of the lower plenum panel. 8. Install and tighten the nut and washer that secures the right engine-to-body ground strap eyelet to the inboard weld stud on the right side of the lower plenum panel. Tighten the nut to 9 Nm (80 in. lbs.). 9. Install and tighten the nut and washer that secures the left engine-to-body ground strap eyelet to the weld stud on the left side of the lower plenum panel. Tighten the nut to 9 Nm (80 in. lbs.). EXHAUST SYSTEM-TO-BODY GROUND STRAP 1. Position the exhaust system-to-body ground strap over the top of the right frame rail. 2. Install and tighten the screw that secures the exhaust system-to-body ground strap eyelet terminal to the right body sill panel. Tighten the screw to 5.0 Nm (45 in. lbs.). 3. Position the exhaust system-to-body ground strap eyelet terminal over the exhaust pipe clamp U-bolt. 4. Install and tighten the nut and washer that secures the exhaust system-to-body ground strap eyelet terminal to the exhaust pipe clamp. Tighten the nut to 27.1 Nm (20 ft. lbs.). 5. Lower the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations Remote Switch: Locations The two remote radio switchs are retained in mounting holes located on each side of the rear steering wheel trim cover by four latches that are integral to the switches. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations > Page 6376 Remote Switch: Diagrams Left Remote Radio Switch (Premium) Right Remote Radio Switch (Premium) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations > Page 6377 Remote Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations > Page 6378 Remote Switch: Description and Operation A remote radio switch option is available on models equipped with the AM/FM/CD/cassette/3-band graphic equalizer radio receiver and the high-line Central Timer Module (CTM). (Refer to ELECTRONIC CONTROL MODULES/BODY CONTROL/CENTRAL TIMER MODULE DESCRIPTION). Fig. 13 Remote Radio Switches Two rocker-type switches are mounted in the sides of the rear (instrument panel side) steering wheel trim cover. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. The switch on the right spoke also includes a "mode" control that allows the driver to sequentially select AM radio, FM radio, cassette player or CD player. The two switches are retained in mounting holes located on each side of the rear steering wheel trim cover by four latches that are integral to the switches. The remote radio switches share a common steering wheel wire harness with the vehicle speed control switches. The steering wheel wire harness is connected to the instrument panel wire harness through the clockspring. (Refer to CLOCKSPRING - DESCRIPTION). The remote radio switches are resistor multiplexed units that are hard wired to the high-line CTM through the clockspring. The CTM monitors the status of the remote radio switches and sends the proper switch status messages on the J1850 data bus network to the radio receiver. The electronic circuitry within the radio is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. For diagnosis of the CTM or the J1850 data bus, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended. For more information on the features and control functions for each of the remote radio switches, see the owner's manual in the vehicle glove box. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations > Page 6379 Remote Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Fig. 14 Remote Radio Switches 1. Remove the remote radio switch(es) from the steering wheel. Remote Radio Switch Test 2. Use an ohmmeter to check the switch resistances as shown in the Remote Radio Switch Test chart. If the remote radio switch resistances check OK, go to Step 3. If not OK, replace the faulty switch. 3. Check for continuity between the ground circuit cavity of the remote radio switch wire harness connector and a good ground. There should be continuity. If OK, go to Step 4. If not OK, repair the open ground circuit to ground as required. 4. Disconnect the 18-way wire harness connector from the Central Timer Module (CTM). Check for continuity between the radio control mux circuit cavity of the remote radio switch wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted radio control mux circuit as required. 5. Check for continuity between the radio control mux circuit cavities of the remote radio switch wire harness connector and the 18-way CTM wire harness connector. There should be continuity. If OK, refer to the proper Diagnostic Procedures to test the CTM and the J1850 data bus. If not OK, repair the open radio control mux circuit as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations > Page 6380 Remote Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side airbag module from the steering wheel. (Refer to DRIVER AIRBAG - REMOVAL). 3. Remove the speed control switch located on the same side of the steering wheel as the remote radio switch that is being serviced. (Refer to SPEED CONTROL/SWITCH - REMOVAL). Fig. 15 Remote Radio Switches Remove/Install 4. Disconnect the steering wheel wire harness connector from the connector receptacle of the remote radio switch. 5. Disengage the four remote radio switch latches that secure the switch to the inside of the mounting hole in the steering wheel rear trim cover 6. From the outside of the steering wheel rear trim cover, remove the remote radio switch from the trim cover mounting hole. INSTALLATION 1. Position the remote radio switch to the mounting hole on the outside of the steering wheel rear trim cover. Be certain that the connector receptacle is oriented toward the bottom of the switch and pointed toward the center of the steering wheel. 2. Press firmly and evenly on the remote radio switch until each of the switch latches is fully engaged in the mounting hole of the steering wheel rear trim cover. 3. Reconnect the steering wheel wire harness connector to the connector receptacle of the remote radio switch. 4. Install the speed control switch onto the steering wheel. (Refer to SPEED CONTROL/SWITCH - INSTALLATION). 5. Install the driver side airbag module onto the steering wheel. (Refer to DRIVER AIRBAG - INSTALLATION). 6. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations Speaker: Locations One full-range 16.5 centimeter (6.5 inch) diameter speaker is located in each front door. There is also one full-range 16.5 centimeter (6.5 inch) diameter speaker located in each rear door. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Page 6384 Speaker: Diagrams Left Front Door Woofer Left Rear Door Woofer Right Front Door Woofer Right Rear Door Woofer Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Page 6385 Speaker: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Page 6386 Speaker: Description and Operation STANDARD The standard equipment speaker system includes speakers in four locations. One full-range 16.5 centimeter (6.5 inch) diameter speaker is located in each front door. There is also one full-range 16.5 centimeter (6.5 inch) diameter speaker located in each rear door. Each of the four full-range speakers used in the standard speaker system is driven by the amplifier that is integral to the factory-installed radio receiver. PREMIUM The optional premium speaker system features eight Infinity model speakers in eight locations. Each of the standard speakers in the front doors is replaced with Infinity model speakers, and an additional 6.9 centimeter (2.75 inch) diameter Infinity dome tweeter is mounted high in the front door trim panels. The standard speakers in the rear doors are each replaced with an Infinity 16.5 centimeter (6.5 inch) diameter unit and a 6.9 centimeter infinity tweeter mounted high in the rear door trim panels. The premium speaker system also includes an additional Infinity power amplifier. The total available power of the premium speaker system is about 120 watts. The eight Infinity speakers used in the premium speaker system are all driven by the radio receiver through an Infinity power amplifier. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Page 6387 Speaker: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. CAUTION: The speaker output of the radio is a "floating ground" system. Do not allow any speaker lead to short to ground, as damage to the radio may result. 1. Turn the ignition switch to the ON position. Turn the radio receiver ON. Adjust the balance and fader controls to check the performance of each individual speaker. Note the speaker locations that are not performing correctly. Go to Step 2. 2. Turn the radio receiver OFF. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Remove the radio receiver from the instrument panel. If the vehicle is equipped with the Infinity speaker package, also disconnect the wire harness connectors at the power amplifier. Check both the speaker feed (+) circuit and return (-) circuit cavities for the inoperative speaker location(s) at the radio receiver wire harness connectors for continuity to ground. In each case, there should be no continuity. If OK, go to Step 3. If not OK, repair the shorted speaker feed (+) and/or return (-) circuit(s) to the speaker as required. 3. If the vehicle is equipped with the Infinity speaker package, go to Step 6. If the vehicle is equipped with the standard speaker system, check the resistance between the speaker feed (+) circuit and return (-) circuit cavities of the radio receiver wire harness connectors for the inoperative speaker location(s). The meter should read between 2 and 28 ohms (speaker resistance). If OK, go to Step 4. If not OK, go to Step 5. 4. Install a known good radio receiver. Connect the battery negative cable. Turn the ignition switch to the ON position. Turn ON the radio receiver and test the speaker operation. If OK, replace the faulty radio receiver. If not OK, turn the radio receiver OFF, turn the ignition switch to the OFF position, disconnect and isolate the battery negative cable, remove the test radio receiver, and go to Step 5. 5. Disconnect the wire harness connector at the inoperative speaker. Check for continuity between the speaker feed (+) circuit cavities of the radio receiver wire harness connector and the speaker wire harness connector. Repeat the check between the speaker return (-) circuit cavities of the radio receiver wire harness connector and the speaker wire harness connector. In each case, there should be continuity. If OK, replace the faulty speaker. If not OK, repair the open speaker feed (+) and/or return (-) circuit(s) as required. 6. For each inoperative speaker location, check for continuity between the speaker feed (+) circuit cavities of the radio receiver wire harness connectors and the power amplifier wire harness connectors. Repeat the check for each inoperative speaker location between the speaker return (-) circuit cavities of the radio receiver wire harness connectors and the power amplifier wire harness connectors. In each case, there should be continuity. If OK, go to Step 7. If not OK, repair the open speaker feed (+) and/or return (-) circuit(s) as required. 7. Check for continuity between the two ground circuit cavities of the power amplifier wire harness connector and a good ground. There should be continuity. If OK, go to Step 8. If not OK, repair the open ground circuit(s) to ground as required. 8. Check the power amplifier fuse in the junction block. If OK, go to Step 9. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 9. Install the radio receiver. Connect the battery negative cable. Check for battery voltage at the power amplifier fuse in the junction block. If OK, go to Step 10. If not OK, repair the open fused B(+) circuit to the PDC as required. 10. Check for battery voltage at the two fused B(+) circuit cavities of the power amplifier wire harness connector. If OK, go to Step 11. If not OK, repair the open fused B(+) circuit(s) to the fuse in the junction block as required. 11. Turn the ignition switch to the ON position. Turn the radio receiver ON. Check for battery voltage at the radio 12 volt output circuit cavity of the power amplifier wire harness connector. If OK, go to Step 12. If not OK, repair the open radio 12 volt output circuit to the radio receiver as required. 12. Turn the radio receiver OFF. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. For each inoperative speaker location, check both the amplified feed (+) circuit and the amplified return (-) circuit cavities of the power amplifier wire harness connectors for continuity to ground. In each case there should be no continuity. If OK, go to Step 13. If not OK, repair the shorted amplified feed (+) and/or amplified return (-) circuit(s) to the speaker as required. 13. For each inoperative speaker location, check the resistance between the amplified feed (+) circuit and the amplified return (-) circuit cavities of the power amplifier wire harness connectors. The meter should read between 2 and 28 ohms (speaker resistance). If OK, replace the faulty power amplifier. If not OK, go to Step 14. 14. Disconnect the speaker wire harness connector at the inoperative speaker. Check for continuity between the amplified feed (+) circuit cavities of the speaker wire harness connector and the power amplifier wire harness connector. Repeat the check between the amplified return (-) circuit cavities of the speaker wire harness connector and the power amplifier wire harness connector. In each case there should be continuity. If OK, replace the faulty speaker. If not OK, repair the open amplified feed (+) and/or amplified return (-) circuit(s) as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Upper Speaker Replacement Speaker: Service and Repair Front Door Upper Speaker Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the front door. 3. Remove the screws that secure the front door upper speaker to the back of the trim panel. 4. Remove the front door upper speaker from the trim panel. INSTALLATION 1. Position the front door upper speaker to the back of the trim panel. 2. Install and tighten the screws that secure the front door upper speaker to the trim panel. Tighten the screws to 1.3 Nm (12 in. lbs.). 3. Reconnect the door wire harness connector to the front door upper speaker wire harness connector. 4. Install the trim panel onto the front door. 5. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Upper Speaker Replacement > Page 6390 Speaker: Service and Repair Front Door Lower Speaker Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the front door. Fig. 16 Front Door Lower Speaker Remove/Install 3. Remove the screws that secure the speaker to the front door. 4. Pull the speaker away from the mounting hole in the front door inner panel far enough to access the wire harness connector. 5. Disconnect the front door wire harness connector from the speaker. 6. Remove the speaker from the front door inner panel. INSTALLATION 1. Position the speaker to the front door. 2. Reconnect the front door wire harness connector to the speaker. 3. Position the speaker into the mounting hole in the front door. 4. Install and tighten the screws that secure the speaker to the front door. Tighten the screws to 2 Nm (17 in. lbs.). 5. Install the trim panel onto the front door. 6. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Upper Speaker Replacement > Page 6391 Speaker: Service and Repair Rear Door Upper Speaker Replacement REMOVAL 1. Disconnect and isolate the battery negative cable 2. Remove the trim panel from the rear door. 3. Remove the screws that secure the rear door upper speaker to the back of the trim panel. 4. Remove the rear door upper speaker from the trim panel. INSTALLATION 1. Position the rear door upper speaker to the back of the trim panel. 2. Install and tighten the screws that secure the rear door upper speaker to the trim panel. Tighten the screws to 1.3 Nm (12 in. lbs.). 3. Reconnect the door wire harness connector to the rear door upper speaker wire harness connector. 4. Install the trim panel onto the rear door. 5. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Upper Speaker Replacement > Page 6392 Speaker: Service and Repair Rear Door Lower Speaker Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the rear door. Fig. 17 Rear Door Speaker Remove/Install - Quad Cab 3. Remove the screws that secure the speaker to the rear door. 4. Pull the speaker away from the mounting hole in the rear door far enough to access the wire harness connector. 5. Disconnect the rear door wire harness connector from the speaker. 6. Remove the speaker from the rear door. INSTALLATION 1. Connect the rear door wire harness connector to the speaker. 2. Position the speaker into the mounting hole in the rear door inner panel. 3. Install and tighten the screws that secure the speaker to the rear door. Tighten the screws to 3.9 Nm (35 in. lbs.). 4. Install the trim panel onto the rear door. 5. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Alarm Module: Locations The SKIM is located on the right side of the steering column, below the ignition lock cylinder housing and is concealed beneath the steering column shrouds. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 6397 Alarm Module: Diagrams Sentry Key Immobilizer Module Sentry Key Immobilizer Module Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 6398 Alarm Module: Description and Operation Fig.10 Sentry Key Immobilizer Module SENTRY KEY IMMOBILIZER MODULE The Sentry Key Immobilizer Module (SKIM) is the primary component of the Sentry Key Immobilizer System (SKIS). The SKIM is located on the right side of the steering column, below the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKIM has an integral molded plastic halo-like antenna ring that extends from one end. When the SKIM is properly installed on the steering column, the antenna ring is oriented around the circumference of the ignition lock cylinder housing. A single integral connector receptacle containing six terminal pins is located on the opposite end of the SKIM housing from the antenna ring. A stamped metal mounting bracket secured to the SKIM housing has a U-shaped clip formation that is used to secure the unit to the right lower flange of the steering column jacket. The SKIM cannot be adjusted or repaired. If faulty or damaged, the entire SKIM unit must be replaced. The Sentry Key Immobilizer Module (SKIM) contains a Radio Frequency (RF) transceiver and a microprocessor. The SKIM transmits RF signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring integral to the SKIM housing. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKIM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKIM also communicates over the Programmable Communications Interface (PCI) data bus with the Powertrain Control Module (PCM), the Electro Mechanical Instrument Cluster (EMIC) and/or the DRB III scan tool. The SKIM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKIM. For added system security, each SKIM is programmed with a unique Secret Key code. This code is stored in memory, sent over the PCI data bus to the PCM, and is encoded to the transponder of every Sentry Key that is programmed into the SKIM. Therefore, the Secret Key code is a common element that is found in every component of the Sentry Key Immobilizer System (SKIS). Another security code, called a PIN, is used to gain access to the SKIM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKIM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a PCI data bus message from the PCM during SKIS initialization. In the event that a SKIM replacement is required, the Secret Key code can be transferred to the new SKIM from the PCM using the DRB III® scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKIM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKIM replacement will also require new Sentry Keys. The DRB III scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the ON position, the SKIM transmits an RF signal to the transponder in the ignition key. The SKIM then waits for an RF signal response from the transponder. If the response received identifies the key as valid, the SKIM sends a valid key message to the PCM over the PCI data bus. If the response received identifies the key as invalid, or if no response is received from the key transponder, the SKIM sends an invalid key message to the PCM. The PCM will enable or disable engine operation based upon the status of the SKIM messages. It is important to note that the default condition in the PCM is an invalid key; therefore, if no message is received from the SKIM by the PCM, the engine will be disabled and the vehicle immobilized after two seconds of running. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 6399 The SKIM also sends SKIS indicator status messages to the EMIC over the PCI data bus to tell the EMIC how to operate the SKIS indicator. This indicator status message tells the EMIC to turn the indicator ON for about three seconds each time the ignition switch is turned to the ON position as a bulb test. After completion of the bulb test, the SKIM sends indicator status messages to the EMIC to turn the indicator off, turn the indicator ON, or to flash the indicator ON and OFF. If the SKIS indicator flashes or stays ON solid after the bulb test, it signifies a SKIS fault. If the SKIM detects a system malfunction and/or the SKIS has become inoperative, the SKIS indicator will stay ON solid. If the SKIM detects an invalid key or if a key transponder-related fault exists, the SKIS indicator will flash. If the vehicle is equipped with the Customer Learn transponder programming feature, the SKIM will also send messages to the EMIC to flash the SKIS indicator and to generate a single audible chime tone whenever the Customer Learn programming mode is being utilized. (Refer to VEHICLE THEFT SECURITY - STANDARD PROCEDURE - SENTRY KEY TRANSPONDER PROGRAMMING). The SKIS performs a self-test each time the ignition switch is turned to the ON position, and will store fault information in the form of Diagnostic Trouble Codes (DTC's) in SKIM memory if a system malfunction is detected. The SKIM can be diagnosed, and any stored DTC's can be retrieved using a DRB III scan tool. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 6400 Alarm Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the steering column opening cover from the instrument panel. 3. If the vehicle is so equipped, grasp the tilt steering column knob firmly and pull it straight rearward to remove it from the tilt steering column adjuster mechanism lever located on the left side of the column just below the multi-function switch control stalk. 4. From below the steering column, remove the two outboard screws that secure the upper shroud to the lower shroud. 5. Push gently inward on both sides of the upper shroud near the parting line between the upper and lower shrouds to release the snap features that secure it to the lower shroud. 6. Remove the upper shroud from the lower shroud. 7. From below the steering column, remove the one center screw that secures the lower shroud to the steering column lock housing. 8. Remove the lower shroud from the steering column. Fig.10 Sentry Key Immobilizer Module 9. Disconnect the instrument panel wire harness connector for the Sentry Key Immobilizer Module (SKIM) from the SKIM connector receptacle. 10. Remove the screw that secures the SKIM to the steering column lock housing. 11. Disengage the SKIM antenna ring from around the ignition lock cylinder housing. INSTALLATION 1. Position the Sentry Key Immobilizer Module (SKIM) onto the steering column with the antenna ring oriented around the ignition lock cylinder housing. 2. Install and tighten the screw that secures the SKIM to the steering column lock housing. Tighten the screw to 2 Nm (20 in. lbs.). 3. Reconnect the instrument panel wire harness connector for the SKIM to the SKIM connector receptacle. 4. Position the lower shroud onto the steering column. 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column lock housing. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud onto the steering column. If the vehicle is equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the openings in the right side of the upper and lower shrouds. 7. Align the snap features on the upper shroud with the receptacles on the lower shroud and apply hand pressure to snap them together. 8. From below the steering column, install and tighten the two screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). 9. If the vehicle is so equipped, align the tilt steering column knob with the tilt steering column adjuster mechanism lever located on the left side of the column just below the multi-function switch control stalk and using hand pressure push the knob firmly onto the lever. 10. Reinstall the steering column opening cover onto the instrument panel. 11. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 6405 Lock Cylinder Switch: Diagrams Driver Cylinder Lock Switch Liftgate Cylinder Lock Switch Passenger Cylinder Lock Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 6406 Lock Cylinder Switch: Description and Operation DOOR CYLINDER LOCK SWITCH A door cylinder lock switch is snapped onto the back of the key lock cylinder inside each front door. The door cylinder lock switch is a resistor multiplexed momentary switch that is hard wired in series between a body ground and the Central Timer Module (CTM) through the front door wire harness. The door cylinder lock switches are driven by the key lock cylinders and contain three internal resistors. One resistor is used for the neutral switch position, one for the Lock position, and one for the Unlock position. The door cylinder lock switches cannot be adjusted or repaired and, if faulty or damaged, they must be replaced. The door cylinder lock switches are actuated by the key lock cylinder when the key is inserted in the lock cylinder and turned to the lock or unlock positions. The door cylinder lock switch closes a path to ground through one of three internal resistors for the Central Timer Module (CTM) when the front door key lock cylinder is in the Lock, Unlock, or Neutral positions. The CTM reads the switch status through an internal pull-up, then uses this information as an input for both power lock system and Vehicle Theft Security System (VTSS) operation. The door cylinder lock switches and circuits can be diagnosed using conventional diagnostic tools and methods. LIFTGATE CYLINDER LOCK SWITCH The liftgate cylinder lock switch is snapped onto the back of the liftgate key lock cylinder inside the liftgate. The liftgate cylinder lock switch is a resistor multiplexed momentary switch that is hard wired in series between a body ground and the Central Timer Module (CTM) through the liftgate wire harness. The liftgate cylinder lock switch is driven by the key lock cylinder and contains three internal resistors. One resistor is used for the neutral switch position, one for the Lock position and one for the Unlock position. The liftgate cylinder lock switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The liftgate cylinder lock switch is actuated by the key lock cylinder when the key is inserted in the lock cylinder and turned to the lock or unlock positions. The liftgate cylinder lock switch closes a path to ground through one of three internal resistors for the Central Timer Module (CTM) when the liftgate key lock cylinder is in the Lock, Unlock, or Neutral positions. The CTM reads the switch status through an internal pull-up, then uses this information as an input for both the power lock system and Vehicle Theft Security System (VTSS) operation. The liftgate cylinder lock switch and circuits can be diagnosed using conventional diagnostic tools and methods. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Testing and Inspection > Door Cylinder Lock Switch Test Lock Cylinder Switch: Testing and Inspection Door Cylinder Lock Switch Test 1. Disconnect the door cylinder lock switch pigtail wire connector from the door wire harness connector. DOOR LOCK CYLINDER SWITCH 2. Using an ohmmeter, perform the switch resistance checks between the two cavities of the door cylinder lock switch pigtail wire connector. Actuate the switch by rotating the key in the door lock cylinder to test for the proper resistance values in each of the three switch positions, as shown in the Door Cylinder Lock Switch chart. 3. If a door cylinder lock switch fails any of the resistance tests, replace the faulty switch as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Testing and Inspection > Door Cylinder Lock Switch Test > Page 6409 Lock Cylinder Switch: Testing and Inspection Liftgate Cylinder Lock Switch Test 1. Disconnect the liftgate cylinder lock switch pigtail wire connector from the liftgate wire harness connector. Liftgate Cylinder Lock Switch 2. Using an ohmmeter, perform the switch resistance checks between the two cavities of the liftgate cylinder lock switch pigtail wire connector. Actuate the switch by rotating the key in the liftgate lock cylinder to test for the proper resistance values in each of the three switch positions, as shown in the Liftgate Cylinder Lock Switch chart. 3. If a liftgate cylinder lock switch fails any of the resistance tests, replace the faulty switch as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Service and Repair > Door Cylinder Lock Switch Replacement Lock Cylinder Switch: Service and Repair Door Cylinder Lock Switch Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door outside latch handle mounting hardware and linkage from the inside of the door. Door Lock Cylinder Switch Remove/Install - Typical 3. From the outside of the door, pull the door outside latch handle out from the door far enough to access the door cylinder lock switch. 4. Disengage the door cylinder lock switch from the back of the lock cylinder. 5. Disconnect the door cylinder lock switch pigtail wire connector from the door wire harness connector. 6. Disengage the retainers that secure the door cylinder lock switch pigtail wire harness to the inner door panel. 7. Remove the door cylinder lock switch from the door. INSTALLATION 1. Position the door cylinder lock switch into the door. 2. Engage the retainers that secure the door cylinder lock switch pigtail wire harness to the inner door panel. 3. Reconnect the door cylinder lock switch pigtail wire connector to the door wire harness connector. 4. Reinstall the door cylinder lock switch onto the back of the lock cylinder. 5. Reinstall the door outside latch handle mounting hardware and linkage on the inside of the door. 6. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Service and Repair > Door Cylinder Lock Switch Replacement > Page 6412 Lock Cylinder Switch: Service and Repair Liftgate Cylinder Lock Switch Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the liftgate inner panel. Liftgate Lock Cylinder Switch Remove/Install 3. Reach through the access hole in the liftgate inner panel to access and disengage the liftgate cylinder lock switch from the back of the lock cylinder. 4. Disconnect the liftgate cylinder lock switch pigtail wire connector from the liftgate wire harness connector. 5. Disengage the retainers that secure the liftgate cylinder lock switch pigtail wire harness to the liftgate inner panel. 6. Remove the liftgate cylinder lock switch from the liftgate. INSTALLATION 1. Position the liftgate cylinder lock switch into the liftgate. 2. Engage the retainers that secure the liftgate cylinder lock switch pigtail wire harness to the liftgate inner panel. 3. Reconnect the liftgate cylinder lock switch pigtail wire connector to the liftgate wire harness connector. 4. Reinstall the trim panel onto the liftgate inner panel. 5. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations Remote Switch: Locations The two remote radio switchs are retained in mounting holes located on each side of the rear steering wheel trim cover by four latches that are integral to the switches. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 6416 Remote Switch: Diagrams Left Remote Radio Switch (Premium) Right Remote Radio Switch (Premium) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 6417 Remote Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 6418 Remote Switch: Description and Operation A remote radio switch option is available on models equipped with the AM/FM/CD/cassette/3-band graphic equalizer radio receiver and the high-line Central Timer Module (CTM). (Refer to ELECTRONIC CONTROL MODULES/BODY CONTROL/CENTRAL TIMER MODULE DESCRIPTION). Fig. 13 Remote Radio Switches Two rocker-type switches are mounted in the sides of the rear (instrument panel side) steering wheel trim cover. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. The switch on the right spoke also includes a "mode" control that allows the driver to sequentially select AM radio, FM radio, cassette player or CD player. The two switches are retained in mounting holes located on each side of the rear steering wheel trim cover by four latches that are integral to the switches. The remote radio switches share a common steering wheel wire harness with the vehicle speed control switches. The steering wheel wire harness is connected to the instrument panel wire harness through the clockspring. (Refer to CLOCKSPRING - DESCRIPTION). The remote radio switches are resistor multiplexed units that are hard wired to the high-line CTM through the clockspring. The CTM monitors the status of the remote radio switches and sends the proper switch status messages on the J1850 data bus network to the radio receiver. The electronic circuitry within the radio is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. For diagnosis of the CTM or the J1850 data bus, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended. For more information on the features and control functions for each of the remote radio switches, see the owner's manual in the vehicle glove box. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 6419 Remote Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Fig. 14 Remote Radio Switches 1. Remove the remote radio switch(es) from the steering wheel. Remote Radio Switch Test 2. Use an ohmmeter to check the switch resistances as shown in the Remote Radio Switch Test chart. If the remote radio switch resistances check OK, go to Step 3. If not OK, replace the faulty switch. 3. Check for continuity between the ground circuit cavity of the remote radio switch wire harness connector and a good ground. There should be continuity. If OK, go to Step 4. If not OK, repair the open ground circuit to ground as required. 4. Disconnect the 18-way wire harness connector from the Central Timer Module (CTM). Check for continuity between the radio control mux circuit cavity of the remote radio switch wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted radio control mux circuit as required. 5. Check for continuity between the radio control mux circuit cavities of the remote radio switch wire harness connector and the 18-way CTM wire harness connector. There should be continuity. If OK, refer to the proper Diagnostic Procedures to test the CTM and the J1850 data bus. If not OK, repair the open radio control mux circuit as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 6420 Remote Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side airbag module from the steering wheel. (Refer to DRIVER AIRBAG - REMOVAL). 3. Remove the speed control switch located on the same side of the steering wheel as the remote radio switch that is being serviced. (Refer to SPEED CONTROL/SWITCH - REMOVAL). Fig. 15 Remote Radio Switches Remove/Install 4. Disconnect the steering wheel wire harness connector from the connector receptacle of the remote radio switch. 5. Disengage the four remote radio switch latches that secure the switch to the inside of the mounting hole in the steering wheel rear trim cover 6. From the outside of the steering wheel rear trim cover, remove the remote radio switch from the trim cover mounting hole. INSTALLATION 1. Position the remote radio switch to the mounting hole on the outside of the steering wheel rear trim cover. Be certain that the connector receptacle is oriented toward the bottom of the switch and pointed toward the center of the steering wheel. 2. Press firmly and evenly on the remote radio switch until each of the switch latches is fully engaged in the mounting hole of the steering wheel rear trim cover. 3. Reconnect the steering wheel wire harness connector to the connector receptacle of the remote radio switch. 4. Install the speed control switch onto the steering wheel. (Refer to SPEED CONTROL/SWITCH - INSTALLATION). 5. Install the driver side airbag module onto the steering wheel. (Refer to DRIVER AIRBAG - INSTALLATION). 6. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Road Temperature Sensor > Component Information > Description and Operation Road Temperature Sensor: Description and Operation AMBIENT TEMPERATURE SENSOR Ambient air temperature is monitored by the compass mini-trip computer module through the ambient temperature sensor. The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the right side of the radiator yoke, behind the radiator grille and in front of the engine compartment. For complete circuit diagrams, refer to Overhead Console in the Contents of Wiring Diagrams. The ambient temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent to it by the compass mini-trip computer module. The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the compass mini-trip computer module. Based upon the resistance in the sensor, the compass mini-trip computer module senses a specific voltage on the temperature sensor signal circuit, which it is programmed to correspond to a specific temperature. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Road Temperature Sensor > Component Information > Description and Operation > Page 6424 Road Temperature Sensor: Testing and Inspection The thermometer function is supported by the ambient temperature sensor, a wiring circuit, and a portion of the compass mini-trip computer module. If any portion of the ambient temperature sensor circuit fails, the compass/thermometer display function will self-diagnose the circuit. An "SC" (short circuit) will appear in the display in place of the temperature, when the sensor is exposed to temperatures above 110 °C (230 °F), or if the sensor circuit is shorted. An "OC", (open circuit) will appear in the display in place of the temperature, when the sensor is exposed to temperatures below -50 °C (-58 ° F), or if the sensor circuit is open. The ambient temperature sensor circuit can also be diagnosed using the following Sensor Test, and Sensor Circuit Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, refer to Compass Mini-Trip Computer in the Diagnosis and Testing. For complete circuit diagrams, refer to Overhead Console in the Contents of Wiring Diagrams. Sensor Test 1. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor wire harness connector. 2. Measure the resistance of the ambient temperature sensor. At -40 °C (-40 °F), the sensor resistance is 336 kilo ohms. At -55 °C (131 °F), the sensor resistance is 2.488 kilo ohms. The sensor resistance should read between these two values. If OK, refer to Sensor Circuit Test in the Diagnosis and Testing. If not OK, replace the faulty ambient temperature sensor. Sensor Circuit Test 1. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor wire harness connector and the overhead console wire harness connector. 2. Connect a jumper wire between the two terminals in the body half of the ambient temperature sensor wire harness connector. 3. Check for continuity between the sensor return circuit and the ambient temperature sensor signal circuit cavities of the roof wire harness overhead console connector. There should be continuity. If OK, go to Step 4. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 4. Remove the jumper wire from the body half of the ambient temperature sensor wire harness connector. Check for continuity between the sensor return circuit cavity of the roof wire harness overhead console connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted sensor return circuit as required. 5. Check for continuity between the ambient temperature sensor signal circuit cavity of the roof wire harness overhead console connector and a good ground. There should be no continuity. If OK, refer to Compass Mini-Trip Computer in the Diagnosis and Testing. If not OK, repair the shorted ambient temperature sensor signal circuit as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Road Temperature Sensor > Component Information > Description and Operation > Page 6425 Road Temperature Sensor: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Fig.6 Ambient Temperatute Sensor Remove/Install 2. Locate the ambient temperature sensor, on the right side of the radiator yoke behind the grille. 3. Disconnect the wire harness connector from the ambient temperature sensor connector receptacle. 4. Remove the one screw that secures the ambient temperature sensor bracket to the radiator yoke. 5. Remove the ambient temperature sensor from the radiator yoke. INSTALLATION 1. Position the ambient temperature sensor onto the radiator yoke. 2. Install and tighten the one screw that secures the ambient temperature sensor bracket to the radiator yoke. Tighten the screw to 5.6 Nm (50 in. lbs.) . 3. Reconnect the wire harness connector to the ambient temperature sensor connector receptacle. 4. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6431 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6432 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6433 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6434 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6435 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6436 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6437 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6438 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6439 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6440 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6441 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6442 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6443 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6444 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6445 Trailer Connector: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6446 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6447 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6448 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6449 Trailer Tow Connector Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair Trailer Hitch: Service and Repair TRAILER HITCH REMOVAL 1. Remove spare tire. 2. Support trailer hitch on a suitable lifting device. Fig. 8 3. Remove fasteners attaching trailer wiring connector to trailer hitch, if equipped (Fig. 8). Fig. 9 4. Remove bolts attaching trailer hitch to frame rails and rear crossmember (Fig. 9). 5. Separate trailer hitch from vehicle. INSTALLATION 1. Position trailer hitch on vehicle. 2. Install the bolts attaching trailer hitch to frame rail and rear crossmember. Tighten bolts to 108 N.m (80 ft.lbs.) torque. 3. Install fasteners attaching trailer wiring connector to trailer hitch, if equipped. 4. Install spare tire. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6457 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6458 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6459 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6460 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6461 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6462 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6463 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6464 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6465 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6466 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6467 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6468 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6469 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6470 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6471 Trailer Connector: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6472 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6473 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6474 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6475 Trailer Tow Connector Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Road Temperature Sensor > Component Information > Description and Operation Road Temperature Sensor: Description and Operation AMBIENT TEMPERATURE SENSOR Ambient air temperature is monitored by the compass mini-trip computer module through the ambient temperature sensor. The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the right side of the radiator yoke, behind the radiator grille and in front of the engine compartment. For complete circuit diagrams, refer to Overhead Console in the Contents of Wiring Diagrams. The ambient temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent to it by the compass mini-trip computer module. The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the compass mini-trip computer module. Based upon the resistance in the sensor, the compass mini-trip computer module senses a specific voltage on the temperature sensor signal circuit, which it is programmed to correspond to a specific temperature. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Road Temperature Sensor > Component Information > Description and Operation > Page 6480 Road Temperature Sensor: Testing and Inspection The thermometer function is supported by the ambient temperature sensor, a wiring circuit, and a portion of the compass mini-trip computer module. If any portion of the ambient temperature sensor circuit fails, the compass/thermometer display function will self-diagnose the circuit. An "SC" (short circuit) will appear in the display in place of the temperature, when the sensor is exposed to temperatures above 110 °C (230 °F), or if the sensor circuit is shorted. An "OC", (open circuit) will appear in the display in place of the temperature, when the sensor is exposed to temperatures below -50 °C (-58 ° F), or if the sensor circuit is open. The ambient temperature sensor circuit can also be diagnosed using the following Sensor Test, and Sensor Circuit Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, refer to Compass Mini-Trip Computer in the Diagnosis and Testing. For complete circuit diagrams, refer to Overhead Console in the Contents of Wiring Diagrams. Sensor Test 1. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor wire harness connector. 2. Measure the resistance of the ambient temperature sensor. At -40 °C (-40 °F), the sensor resistance is 336 kilo ohms. At -55 °C (131 °F), the sensor resistance is 2.488 kilo ohms. The sensor resistance should read between these two values. If OK, refer to Sensor Circuit Test in the Diagnosis and Testing. If not OK, replace the faulty ambient temperature sensor. Sensor Circuit Test 1. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor wire harness connector and the overhead console wire harness connector. 2. Connect a jumper wire between the two terminals in the body half of the ambient temperature sensor wire harness connector. 3. Check for continuity between the sensor return circuit and the ambient temperature sensor signal circuit cavities of the roof wire harness overhead console connector. There should be continuity. If OK, go to Step 4. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 4. Remove the jumper wire from the body half of the ambient temperature sensor wire harness connector. Check for continuity between the sensor return circuit cavity of the roof wire harness overhead console connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted sensor return circuit as required. 5. Check for continuity between the ambient temperature sensor signal circuit cavity of the roof wire harness overhead console connector and a good ground. There should be no continuity. If OK, refer to Compass Mini-Trip Computer in the Diagnosis and Testing. If not OK, repair the shorted ambient temperature sensor signal circuit as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Road Temperature Sensor > Component Information > Description and Operation > Page 6481 Road Temperature Sensor: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Fig.6 Ambient Temperatute Sensor Remove/Install 2. Locate the ambient temperature sensor, on the right side of the radiator yoke behind the grille. 3. Disconnect the wire harness connector from the ambient temperature sensor connector receptacle. 4. Remove the one screw that secures the ambient temperature sensor bracket to the radiator yoke. 5. Remove the ambient temperature sensor from the radiator yoke. INSTALLATION 1. Position the ambient temperature sensor onto the radiator yoke. 2. Install and tighten the one screw that secures the ambient temperature sensor bracket to the radiator yoke. Tighten the screw to 5.6 Nm (50 in. lbs.) . 3. Reconnect the wire harness connector to the ambient temperature sensor connector receptacle. 4. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions Central Timer Module: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6488 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6489 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6490 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6491 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6492 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6493 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6494 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6495 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6496 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6497 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6498 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6499 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6500 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6501 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6502 Central Timer Module: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6503 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6504 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6505 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6506 Central Timer Module: Electrical Diagrams 8w-45-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6507 8w-45-3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6508 8w-45-4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6509 8w-45-5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6510 8w-45-6 (Base) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6511 8w-45-7 (Light Package) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6512 8w-45-8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6513 8w-45-9 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6514 8w-45-10 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6515 8w-45-11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6516 8w-45-12 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6517 8w-45-13 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6518 8w-45-14 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 6519 8w-45-15 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information Central Timer Module: Technician Safety Information WARNING: - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. 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. - NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information > Page 6522 Central Timer Module: Vehicle Damage Warnings Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. 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, Road Testing A Complaint Vehicle Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE REASSEMBLED. DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB III SCREEN WHILE IN MOTION. DO NOT HANG THE DRB III FROM THE REAR VIEW MIRROR OR OPERATE IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB III. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description Central Timer Module: Description and Operation Sytem Description The body system on the 2001 DN consists of a combination of modules that communicate over the PCI bus (Programmable Communication Interface multiplex system). Through the PCI bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all information to perform its function. It will only respond to messages "addressed" to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. All of the information about the functioning of all the systems is organized, controlled, and communicated by the PCI bus, which is described in the vehicle communication of this general information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 6525 Central Timer Module: Description and Operation Functional Operation Part 1 of 2 For additional information on the Base CTM refer to Instrument Panel, Gauges and Warning Indicators / Audible Warning Device. See: Instrument Panel, Gauges and Warning Indicators/Audible Warning Device AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. The Airbag Control Module (ACM) is an electronic module that monitors the airbag system for proper operation, stores diagnostic trouble code (DTCs), controls the airbag warning lamp and contains the sensor and actuator that is responsible for airbag deployment. There are no external impact sensors. The ACM is mounted on a special bracket that is fastened to the floor of the truck at the bottom of the instrument panel. It is located forward of the console. The ACM provides diagnostic information (DTCs) to the technician through the DRB III via the PCI bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp is driven with messages relayed to the Electro/Mechanical Instrument Cluster (EMIC) from the ACM via the PCI bus. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Whenever the ignition key is turned to the "run" or "start" position, the airbag control module performs a lamp check by turning the AIRBAG warning lamp ON for 6 - 8 seconds. If the lamp remains OFF, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains ON, there could be an active fault in the system or the circuit that operates the lamp may be shorted to ground. If the lamp comes ON and stays ON for a period longer than 6 - 8 seconds, then goes OFF, there is usually an intermittent problem in the system. WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. 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. - NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. Seat Belt Tensioner Front seat belt systems incorporate Tensioner Modules (SBT). At the onset of an impact event each tensioner uses a pyrotechnic device, which is triggered simultaneously with the airbags, to rapidly retract the seat belts. With the slack removed, the occupant's forward motion in an impact will be reduced as will the likelihood of contacting interior components. After an impact that deploys the airbag, the seat belt tensioner assembly must be replaced. The ACM module monitors the Seat Belt Tensioners circuit resistance and reports active and stored DTC's if any problem is found. Airbag Diagnostic Trouble Codes Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB III. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures, diagnostic trouble codes are used as a diagnostic tool. Active Codes The code becomes active as soon as the malfunction is detected and stored after one minute of occurrence or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 6526 of 12 seconds or as long as the malfunction is present. Stored Codes Airbag codes are automatically stored in the ACM's memory after one minute of occurrence or when the ignition is turned OFF. The exception is the "Loss of Ignition Run Only" code which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored as long as the malfunction exists. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, that diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "ON" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. AUDIO SYSTEM The factory installed radio receiver communicates on the Programmable Communication Interface (PCI) data bus network through a separate two-way wire harness connector. This is used for the remote radio switches that are mounted to the steering wheel, and also used for radio diagnosis with the DRB III. The remote radio switches are resistor multiplexed units that are hard wired to the CTM through the clockspring. The CTM monitors the status of the remote radio switches and sends the proper switch status messages on the PCI data bus network to the radio receiver. The electronic circuitry within the radio is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. When troubleshooting output shorts or "output" error messages, the following applies: On radios without an external amplifier, the term "output" refers to the path between the radio and the speaker. This type of circuit can be monitored all the way through the speaker connections by the radio assembly. When the radio displays a shorted output DTC with this type of system, the speaker, radio or wiring could be at fault. The output DTC could refer to a front or rear output or a left or right output. The reason for the difference is the pairing of the output sections of the radio. Some are paired left and right, others are paired front and rear. On radios with an external amplifier, the term "output" refers to the circuit between the radio connector and the amplifier. The radio is capable of monitoring only this portion and can tell nothing about the circuit between the amplifier and the speakers. Consequently, a shorted output DTC on this type of system would only refer to this circuit. A faulty speaker could not cause this DTC. CENTRAL TIMER MODULE The Durango (DN) utilizes a Central Timer Module (CTM). This system is available in a Base or Highline configuration. The CTM performs most of the typical functions a Body Control Module would perform. The Base and Highline CTM provides the following features: Battery Saver Functions For Exterior and Interior Lamps - Cargo Lamps - Chime Warning - Courtesy Lamps - Dome Lamps - Dome Defeat - Door Ajar Switch Status - Fog Lamps - Head Lamp Time Delay - Intermittent Wiper Controls - Low and High Beam Head Lamps - Optical Horn - Park Lamps Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 6527 Additional features of Highline CTM Central Locking (VTSS) - Door Lock Inhibit - Driver Door Unlock - Enhanced Accident Response - Power Door Locks - Remote Radio - Remote Keyless Entry - Vehicle Theft Alarm (VTSS) The Central Timer Module is located behind the left side kick panel. It contains 26-way, 16-way and 12-way connectors. CHIME SYSTEM The chime system is built into the CTM. There are two chime rates, Low: 50 chimes per minute for reminders and High: 180 chimes per minute for serious conditions that require immediate attention. The high rate chime sounds when the key is left in the ignition and the driver's door is open or if the headlights or the courtesy lights are left on. The low rate chime sounds for any of the other conditions. There is a variable rate feature that allows the chime to sound continuously for key-in and headlamp warning as long as the door is open. The seat belt warning chime is activated for six seconds, and all other chime conditions will activate the chime once at the same time the warning light on the cluster is illuminated. The Chime will sound for the following conditions: Ignition OFF key in ignition, driver's door open - Ignition OFF, headlamps ON, driver's door open - Ignition OFF, courtesy lamps ON, driver's door open - Seat belt warning (after prove-out) - Malfunction Indicator lamp (MIL) illuminated (after prove-out) - Airbag lamp illuminated (after prove-out) - Check gauges lamp - Low fuel warning - Low washer fluid lamp - Door ajar warning - Transmission temperature lamp - Turn signal on reminder warning - Button pushed on compass mini-trip computer COMPASS MINI-TRIP COMPUTER (CMTC) This system, located in the overhead console, displays information on outside temperature, compass direction and trip information. Compass and Temperature Display This display provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. Trip Odometer (ODO) Shows the distance traveled since the last reset. Average Fuel Economy (AVE ECO) Shows the average fuel economy in MPG (miles per gallon) or L/100 Km since the last reset. Instant Fuel Economy Shows the fuel economy for the last few seconds in MPG or L/100 Km. Distance to Empty (DTE) Shows the estimated distance that can be traveled with the fuel remaining in the tank. This is calibrated using the MPG for the last few minutes. Elapsed Time (ET) Shows the accumulated ignition ON time since the last reset. Step Button Press this button to cycle through all the mini-trip computer displays. US/M Button Press this button to convert all vehicle displays from US to Metric to US. To Reset the Display Press the Step and US/M buttons simultaneously for at least two seconds and all resettable conditions will be reset. This will occur only if a resettable function (AVG ECO, ECO, ET) is currently being displayed. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 6528 Automatic Compass Calibration This compass is self calibrating which eliminates the need to manually set the compass. When the vehicle is new, the compass may appear erratic and the CAL symbol will be displayed. After completing three 360' turns in an area free from large metal or metallic objects, the CAL symbol will turn OFF and the compass will function normally. Compass Variance Compass Variance is the difference between Magnetic North and Geographic North. In some areas of the country, the difference between Magnetic and Geographic North is great enough to cause the compass to give false readings. If this occurs, the compass variance must be set. To Set the Variance Turn the ignition ON and set display to Comp./Temp. while pressing the US/M button, press the STEP button for approximately five seconds. The "VAR" symbol will light and the last variance zone number will be displayed. Press the US/Metric Button to select the proper variance zone as shown on the map. Press the Step button to set the new variance zone and resume normal operation. ELECTRO/MECHANICAL INSTRUMENT CLUSTER (EMIC) The Instrument Cluster contains a Fuel, Voltmeter, Coolant Temp, and Oil Pressure gauge, a Tachometer and a Speedometer. With the exception of the Voltmeter, the cluster positions the gauges with PCI Bus messages received from the PCM. The Voltmeter operates directly off of the Fused B+ Switched Ignition Output circuit that supplies ignition voltage for the cluster. The Instrument Cluster also contains warning indicators that are illuminated by hard wired inputs or by messages received from other modules on the PCI Bus. The Trip/Total Odometer is a Vacuum Fluorescent Display (VF) that is controlled by PCI Bus messages received from the PCM. The cluster illumination lamps are hard wired in the Instrument Cluster. When the Park or Headlamps are turned ON, the cluster receives a dimmed battery feed from the Headlamp Switch. The cluster I/O Processor controls the VF display dimming and also sends dimming level messages on the PCI Bus. The EMIC will communicate with the DRB III to display PCI Engine Info, PCI Bus Info, and certain input/outputs. Cluster diagnostic capabilities that the DRB III will actuate are limited to the Cluster Calibration Points for the gauges. The DRB III can also extract active and stored Diagnostic Trouble Codes (DTC) from the Instrument Cluster. The EMIC is also capable of performing a diagnostic Self-Test that is actuated by depressing and holding the Odometer trip reset stalk while cycling the ignition from the OFF to the ON position. After the cluster Odometer displays CHEC, releasing the reset stalk begins the test. The cluster will then position all of the gauges at specified calibration points and will illuminate all the PCI Bus controlled indicators. The cluster will also illuminate each segment of the VF display. The EMIC can verify communications with the PCM, ID the module, or change the country code using the DRB III. ENHANCED ACCIDENT RESPONSE (HIGHLINE CTM ONLY) If the Airbag Control Module (ACM) deploys the airbags, a message is transmitted over the PCI bus to the CTM module to unlock the doors. The interior lights will be turned ON when the vehicle speed message on the PCI bus indicates 0 mph or the message is not present. In addition to unlocking the doors, the door lock feature will be disabled for a predetermined amount of time following the deployment. Once the ignition key has been cycled to the "OFF" position, normal operation will resume. EXTERIOR LIGHTING The low and high beam headlamps are controlled directly by an output from the Central Timer Module (CTM). The park lamps and fog lamps (on vehicle so equipped) are controlled via external relays that are energized by the CTM. The headlamp switch provides the control signal through the multifunction switch to the CTM, which indicates low or high beam operation. The Optical Horn (Flash to Pass) feature operates both the high beam and low beam headlamps. The CTM provides the Headlamp Time Delay feature. To start the delay, turn the ignition OFF while the headlamps are ON. Then turn the headlamp switch to the OFF position. This has to be done within 45 seconds of the ignition being turned OFF. The headlamps will remain ON for 60 ± 5 seconds. If during this delay period the headlamp switch is turned ON and then OFF, or ignition switch is turned ON delay will be canceled and they will turn OFF immediately. During the delay period, only headlamps are turned ON and park lamps/fog lamps are turned OFF. The CTM also provides battery protection to avoid wearing down the battery if the customer leaves the park lamps or headlamps ON for extended period of time with the ignition OFF. If the park lamps or headlamps remain ON for more than 5 minutes while the ignition is OFF, the headlamps and park lamps shall be turned off and the input causing the lamps to be ON will be ignored until the input is corrected. Once the 5 minute timeout has extinguished the headlamps and park lamps, any change in the ignition switch, door ajar switches, headlamps switch or park lamp switch will reset the 5 minute timer and return the headlamps and park lamps to normal operation. Part 2 of 2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 6529 HEATING & A/C SYSTEM The all-new heating and air conditioning system for DN provides more heating and cooling capacity than in previous years. Depending on the model, either a Dual-Zone Air Conditioning System or a Three-Zone Air Conditioning System is currently available in these vehicles. Air Distribution (Front) The front compartment HVAC unit has four fully adjustable instrument panel outlets. Side-window demister outlets in the instrument panel eliminate the need for door ducts and door-to-instrument panel seals. A single central mounted outlet delivers air for defrosting the windshield. Two outlets, one on each side of the center console underneath the instrument panel, provide airflow to the driver floor area and to the front seat passenger floor area. While two additional outlets, one on each side of the center console near the rear of the front seats, distribute both heated and cooled air across the floor to the intermediate seat passengers. Ducts in the center of the vehicle underneath the carpet deliver air from the front compartment HVAC unit to the two intermediate passenger outlets. Door Actuator Control A simplified control system for operation of the mode, recirculation, and temperature control actuators provides positive positioning without the complexity of feedback from position sensors. The A/C - Heater Control Module knows the number of operating actuator revolutions required for full door travel as well as the number of actuator commutator pulses per revolution. Using these parameters, the A/C - Heater Control Module runs the actuator for the number of commutator pulses that correspond to the desired door position. To maintain accuracy, the system recalibrates itself periodically at known zero and full travel conditions. The dual sliding Blend switches have multiple detents to control the full range of temperature that the system can produce in any mode. On Dual-Zone systems, the upper slide pot controls the driver-side blend door and the lower slide pot controls the passenger-side blend door. On Three-Zone systems, the upper slide pot controls the driver-side blend door, while the lower slide pot controls the passenger-side blend door and the rear A/C - heater unit blend door. The single rotary Mode switch has 12 detents to either direct airflow to the panel outlets, to a mix of floor and panel outlets, to the floor outlets, to a mix of floor and defrost outlets, or to the defrost outlet. Rotating the Mode switch to either of the two MAX positions results in the A/C - Heater Control Module sending a signal to the recirculation actuator to close the fresh-air door. While rotating the Mode switch to any other position results in the A/C - Heater Control Module sending a signal to the recirculation actuator to open the fresh-air door. When the Blower switch is OFF, the A/C - Heater Control Module closes the fresh-air door to prevent outside air from entering the vehicle. On Three- Zone systems, the Mode switch also controls the rear A/C - heater unit mode door, which directs rear airflow either to the right quarter trim panel outlet or to the overhead outlets. Front Blower Control The front blower circuitry employs a new resistor technology to control front blower speed. Called the "credit card" resistor, the device looks much like its name in that it is thin and compact like a credit card. The credit card resistor, like the coil resistor used in previous years, mounts inside the front HVAC housing assembly in the airflow path. However, unlike the coil resistor, the credit card resistor offers much less airflow restriction. A/C Operation The A/C - Heater Control Module monitors the temperature of the evaporator to keep it just above freezing for maximum cooling and dehumidification. A thermistor (temperature variable resistor) placed between the evaporator fins provides the signal for the control. The Powertrain Control Module (PCM) cycles the compressor on and off with a signal from the A/C - Heater Control Module. Heater Operation To assist the HVAC system in maintaining a consistent and optimum heat output at low vehicle speeds, an electric coolant pump operates under specific conditions to keep a steady flow of hot coolant circulating through the heater circuit. The A/C - Heater Control Modules controls the operation of the electric coolant pump. The pump runs when all of the following conditions are met: When the vehicle's speed is below 27 Km/h (17 mph), the coolant temperature is between 65.5 °C and 110 °C (150 °F and 230 °F), and the blend control is set above 60% reheat. The A/C - Heater Control Module turns the pump OFF if any one of the following conditions occur: The vehicle speed rises above 48.3 Km/h (30 mph). The coolant temperature drops below 65.5 °C (150 °F). The coolant temperature rises above 110 °C (230 °F). The blend control is set below 60% reheat. A/C - Heater Control (Rear) The Three-Zone system allows the intermediate seat occupants to regulate the air temperature and the fan speed of the rear unit from the rotary controls on the headliner mounted Rear A/C - Heater Control. HVAC Diagnostics The A/C - Heater Control Module is fully addressable with the DRB III. Two of the Control Module's diagnostic capabilities that the DRB III will actuate include the A/C Cool down Test to test A/C system performance and the HVAC Door Recalibration Test to determine actuator travel span. After performing either test, the Control Module will display one or more messages on the DRB III screen. The message will indicate either that the HVAC system passed the test or that there is a fault currently active in the HVAC system. The DRB III can also extract active and stored Diagnostic Trouble Codes (DTCs) from the control module. Active DTCs are faults that currently exit in the HVAC system. Stored DTCs are faults that occurred in the HVAC system since the control module received the last "clear diagnostic info" message. INTERIOR LIGHTING Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 6530 The Courtesy lights and illuminated entry feature are controlled by the Central Timer Module (CTM). The CTM will activate the courtesy lamps, including Map Lights and the Dome Lights when either the dome lamp switch is turned ON or a door is opened. The courtesy lamps will fade to OFF immediately when all doors are closed with the dome lamp switch in the OFF position. The illuminated entry feature operates under the following conditions: RKE "unlock" - Driver/Passenger door is opened - Unlocking either the driver or passenger using the key (vehicles equipped with security system) - The dome lamp switch is turned ON Once activated, the illuminated entry will "fade to OFF" after 3 to 5 seconds under the following conditions: All doors are closed and: RKE "lock signal is received or - Manual actuated power "lock" signal is received or - Ignition switch is turned to the ON position or - 30 seconds have elapsed without any other action Addition RKE unlock actuation before the expiration of illuminated entry will not reset timer. Opening any door before the 30 second timer expires, will reset the entry time to 30 seconds and the illuminated entry timer will not begin counting down again until all doors are closed. The Cargo lamps are controlled by the CTM. Placing the dome lamp switch in the cargo lamp position grounds an input to the CTM. The CTM then sends voltage to the cargo lamps. The Interior lamp defeat feature will not allow any interior lamp to be turned ON. This is accomplished through an input to the CTM from the dome lamp switch. The CTM provides battery protection by shutting down the interior lamps due to the following. Leaving a door open, dome lamp switch ON, reading/vanity lamp switch ON or glove box door open for more than 15 minutes while the ignition is OFF. POWER DOOR LOCKS/REMOTE KEYLESS ENTRY The CTM controls the door lock actuator assemblies to handle locking and unlocking with the key fob or interior switch. Vehicles that are equipped with the Vehicle Theft Security System will also have the central locking feature. With the central locking feature, when the cylinder lock switch is turned to the lock position all the doors will lock. For unlocking, if the key is turned to the unlock position once, only that door will unlock. If the key is then turned a second time to the unlock position, all the doors will unlock. There is also a door lock inhibit feature that prevents power locking of the doors if the ignition is OFF and the key is in the ignition. Automatic or "rolling locks" are included as a programmable feature. If the vehicle is moving approximately 15 mph and approximately 10 degrees of throttle opening is seen by the PCM, (the PCM will send this info to the CTM via the PCI bus) indicating acceleration, the CTM will cycle the lock actuators to lock the doors. The highline CTM provides for Remote Keyless Entry (RKE) The RKE system is placed in the programming mode by the DRB III, or by the customer program features. The system will store up to four key fob codes. Two fobs are supplied with the truck, additional fobs may be purchased through the parts department. Through the DRB III, erasing and programming of one key fob without deleting the others is possible. If the key fob is stolen, all the fob codes stored previously may be erased to provide the owner of the vehicle with an extra sense of security. VEHICLE COMMUNICATION The Programmable Communication Interface or PCI Bus is a single wire multiplexed network capable of supporting binary encoded messages shared between multiple modules. The PCI bus circuit is identified as D25 and is violet with a yellow tracer. Additional tracer colors may be added to the yellow in order to distinguish between different module connections. The modules are wired in parallel. Connections are made in the harness using a splice. The splice called the Diagnostic Junction Port, serves as the "Hub" of the bus. The Diagnostic Junction Port provides an access point to isolate most of the modules on the bus in order to assist in diagnosing the circuit. The following modules are used on the DN: Airbag Control Module - A/C Heater Control - Central Timer Module - Controller Antilock Brake - Compass Mini-Trip Computer - Electro/Mechanical Instrument Cluster - Powertrain Control Module - Radio Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 6531 - Sentry Key Immobilizer Module - Transfer Case Control Module - Transmission Control Module Each module provides its own bias and termination in order to transmit and receive messages. The bus voltage is at zero volts when no modules are transmitting and is pulled up to about seven and a half volts when modules are transmitting. The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRB III lab scope. The 12v square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between zero and about seven and a half volts. Refer to the figure for some typical displays. The PCI Bus failure modes are broken down into two categories. Complete PCI Bus Communication Failure and individual module no response. Causes of complete PCI Bus Communication Failure include a short to ground or battery on the PCI circuit. Individual module no response can be caused by an open circuit at either the Diagnostic Junction Port or the module, or an open battery or ground circuit to the affected module. Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: All gauges on the EMIC stay at zero - All telltales on EMIC illuminate - EMIC backlighting at full intensity - Dashed lines in the Compass Mini-Trip Computer display Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Sytem Description > Page 6532 - No response received from any module on the PCI bus (except the PCM) - No start (if equipped with Sentry Key immobilizer) Symptoms of Individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRB III. Diagnosis starts with symptom identification. If a complete PCI Bus Communication Failure is suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRB III. If any modules are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI circuit or power supply and ground circuits. The DRB III may display "BUS +A SIGNAL OPEN" or "NO RESPONSE" to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRB III and in no way indicates whether or not the PCI bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped. VEHICLE THEFT SECURITY SYSTEM The VTSS system monitors the door ajar switches, and ignition switch to detect unauthorized entry into the vehicle. Once the vehicle is "armed", any one of these inputs can cause the VTSS system to be tripped. Once tripped, the horn and lights will pulse for 3 minutes and if an attempt is made to start the engine with a non-programmed SKIM key, it will start and stall. If the trigger condition is still present, the lights will continue to flash for an additional 15 minutes, after which the system will stop pulsing the lights and return to the "armed" state. The cause of the last 4 alarm triggers is stored by the CTM and may be retrieved by the DRB III. The system may be disarmed by either an unlock command from a valid RKE key fob by using a key in either door, or by using a valid SKIM key in the ignition. The door key cylinders are equipped with disarm switches. There is also a VTSS lamp on the dash that provides information to the driver about the state of the vehicle theft system. WINDSHIELD WIPER SYSTEM The DN truck is equipped with speed sensitive intermittent wipers. The low and high speeds are controlled through the wiper stalk switch. The intermittent portion of the wiper control is handled by the CTM through the intermittent wiper relay. When the module detects a decrease in delay time as selected by the driver, an immediate wipe of the windshield takes place and the new delay interval is implemented. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Central Timer Module: Symptom Related Diagnostic Procedures Non-Trouble Code Procedures For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. The hard wired inputs to and outputs from the Central Timer Module (CTM) may be diagnosed and tested using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the CTM. In order to obtain conclusive testing of the CTM, the Programmable Communications Interface (PCI) data bus network and all of the electronic modules that provide inputs to or receive outputs from the CTM must also be checked. The most reliable, efficient, and accurate means to diagnose the CTM, the PCI data bus network, and the electronic modules that provide inputs to or receive outputs from the CTM requires the use of a DRB III scan tool. Refer to the appropriate diagnostic information. The DRB III scan tool can provide confirmation that the PCI data bus network is functional, that all of the electronic modules are sending and receiving the proper messages over the PCI data bus, and that the CTM is receiving the proper hard wired inputs and responding with the proper hard wired outputs needed to perform its many functions. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: The following tests may not prove conclusive in the diagnosis of the Central Timer Module (CTM). The most reliable, efficient, and accurate means to diagnose the CTM requires the use of a DRB III scan tool. Refer to the appropriate diagnostic information. 1. Check the fused B(+) fuses (Fuse 3 - 20 ampere, and Fuse 12 - 20 ampere) in the Power Distribution Center (PDC). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fused B(+) fuses (Fuse 3 - 20 ampere, and Fuse 12 - 20 ampere) in the PDC. If OK, go to Step 3. If not OK, repair the open B(+) circuit between the PDC and the battery as required. 3. Disconnect and isolate the battery negative cable. Disconnect the instrument panel wire harness connector (Connector C3) for the CTM from the CTM connector receptacle. Reconnect the battery negative cable. Check for battery voltage at each of the two fused B(+) circuit cavities of the instrument panel wire harness connector (Connector C3) for the CTM. If OK, disconnect and isolate the battery negative cable, reconnect the instrument panel wire harness connector (Connector C3) for the CTM to the CTM connector receptacle, and go to Step 4. If not OK, repair the open fused B(+) circuit(s) between the CTM and the PDC as required. 4. Check the fused ignition switch output (run-start) fuse (Fuse 11 - 10 ampere) and the fused ignition switch output (run-acc) fuse (Fuse 5 - 20 ampere) in the Junction Block (JB). If OK, go to Step 5. If not OK, repair the shorted circuit or component as required and replace the faulty fuse(s). 5. Reconnect the battery negative cable. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run-start) fuse (Fuse 11 - 10 ampere) and the fused ignition switch output (run-acc) fuse (Fuse 5 20 ampere) in the JB. If OK, go to Step 6. If not OK, repair the open fused ignition switch output (run-start) circuit or fused ignition switch output (run-acc) circuit between the JB and the ignition switch as required. 6. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the instrument panel wire harness connector (Connector C1) for the CTM from the CTM connector receptacle. Reconnect the battery negative cable. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run-start) circuit cavity and the fused ignition switch output (run-acc) cavity of the instrument panel wire harness connector (Connector C1) for the CTM. If OK, go to Step 7. If not OK, repair the open fused ignition switch output (run-start) circuit or fused ignition switch output (run-acc) circuit between the CTM and the JB as required. 7. Turn the ignition switch to the OFF position. Check for continuity between each of the three ground circuits in the instrument panel wire harness connector (Connector C1) for the CTM and a good ground. In each case there should be continuity. If OK, use a DRB III scan tool to perform further diagnosis of the CTM. Refer to the appropriate diagnostic information. If not OK, repair the open ground circuit(s) to ground (G207 or G208) as required. Chime Inoperative At All Times Test 1 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6535 SYMPTOM CHIME INOPERATIVE AT ALL TIMES POSSIBLE CAUSES - CTM - Chime inoperative Chime Inoperative With Drivers Seat Belt Unfastened Tests 1 - 4 SYMPTOM CHIME INOPERATIVE WITH DRIVER SEAT BELT UNFASTENED POSSIBLE CAUSES - Seat belt switch status wrong - Seat belt switch shorted - Seat belt indicator driver wire short to ground - Instrument cluster - seat belt switch shorted Chime Inoperative With Key In Ignition and Driver's Door Open Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6536 Tests 1 - 4 Test 5 SYMPTOM CHIME INOPERATIVE WITH KEY IN IGNITION, DRIVER'S DOOR OPEN POSSIBLE CAUSES - Driver door ajar status - Ignition switch ground circuit open - Key-in ignition switch open - Key-in ignition switch sense circuit open - Central timer module Chime Inoperative, Exterior/Interior Lamps On, Driver Door Open Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6537 Tests 1 - 2 SYMPTOM CHIME INOPERATIVE WITH EXTERIOR OR INTERIOR LAMPS ON WITH DRIVER DOOR OPEN POSSIBLE CAUSES - DRB check driver door ajar - CTM-chime inoperative with headlamp switch - Operation of exterior or interior lighting system Chime Sounds With Driver Seat Belt Fastened Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6538 Tests 1 - 4 Test 5 SYMPTOM CHIME SOUNDS WITH DRIVER SEAT BELT FASTENED POSSIBLE CAUSES - Seat belt switch status wrong - Seat belt switch open - Ground wire open - Seat belt indicator driver wire open - Instrument cluster - seat belt sense open Chime Sounds With Drivers Door Open and Key Removed From Ignition Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6539 Tests 1 - 4 SYMPTOM CHIME SOUNDS WITH DRIVER'S DOOR OPEN, KEY REMOVED POSSIBLE CAUSES - Operation of exterior or interior lighting system - Key-in ignition switch shorted - Key-in ignition SW sense short to ground - Central timer module - key-in ignition shorted Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6540 Central Timer Module: Component Tests and General Diagnostics Road Testing A Complaint Vehicle ROAD TEST WARNINGS Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the test drive, do not try to read the DRB III screen while in motion. Do not hang the DRB III from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB III. Six Step Troubleshooting Procedure SIX-STEP TROUBLESHOOTING PROCEDURE Diagnosis is done in six basic steps: 1. Verification of complaint 2. Verification of any related symptoms 3. Symptom analysis 4. Problem isolation 5. Repair of isolated problem 6. Verification of proper operation Vehicle Preparation For Testing VEHICLE PREPARATION FOR TESTING Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6541 Central Timer Module: Scan Tool Testing and Procedures DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB III will display one of only two error messages: User-Requested WARM Boot (Press MORE and NO at the same time) User-Requested COLD Boot (Press MORE and YES at the same time) If the DRB III should display any other error message, record the entire display and call the S.T.A.R. Center for information and assistance. DRB III DOES NOT POWER UP If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB III. If all connections are proper between the DRB III and the vehicle or other devices, and the vehicle battery is fully charged, and inoperative DRB III may be the result of faulty cable or vehicle wiring. For a blank screen, refer to the appropriate body diagnostics. DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition SOME DISPLAY ITEMS READ "---" This is caused by scrolling the DRB III display a single line up or down. The line which was scrolled onto the screen might read "---". Use the Page Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6542 Down or Page Up function to display the information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Page 6543 Central Timer Module: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: Before replacing a Central Timer Module (CTM), use a DRB III scan tool to retrieve the current settings for the CTM programmable features. Refer to the appropriate diagnostic information. These settings should be duplicated in the replacement CTM using the DRB III scan tool before returning the vehicle to service. 1. Disconnect and isolate the battery negative cable. 2. Remove the trim from the left cowl side inner panel. Fig. 2 Central Timer Module 3. Disconnect the two instrument panel wire harness connectors and one body wire harness connector from the CTM connector receptacles. 4. Remove the three screws that secure the CTM to the left cowl side inner panel. 5. Remove the CTM from the left cowl side inner panel. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: Before replacing a Central Timer Module (CTM), use a DRB III scan tool to retrieve the current settings for the CTM programmable features. Refer to the appropriate diagnostic information. These settings should be duplicated in the replacement high-line/premium CTM using the DRB III scan tool before returning the vehicle to service. 1. Position the CTM onto the left cowl side inner panel. 2. Install and tighten the three screws that secure the CTM to the left cowl side inner panel. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the two instrument panel wire harness connectors and one body wire harness connector to the CTM connector receptacles. 4. Reinstall the trim onto the left cowl side inner panel. 5. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Page 6544 Central Timer Module: Tools and Equipment DRB III (Diagnostic Read-out Box) Jumper Wires Ohmmeter Voltmeter Test Light Diagnostic Junction Port Tester 8310 Airbag Load Tool 8443 Airbag Load Tool Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair Auxiliary Step / Running Board: Service and Repair RUNNING BOARD REMOVAL NOTE: The running boards can be removed and installed on the vehicle as an assembly. 1. Remove the fasteners from the wheel opening molding. 2. Remove the fasteners retaining the running board brackets to the body. 3. Separate the running boards from the vehicle. INSTALLATI0N 1. Position the running boards on the vehicle. 2. Install the bolts retaining the running board brackets to the body. 3. Install the fasteners in the wheel opening molding. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Bracket > System Information > Service and Repair Front Bumper Bracket: Service and Repair FRONT INNER BRACKET REMOVAL 1. Remove bolts attaching top of bumper to bumper bracket. Fig. 1 2. Remove nuts attaching inner bumper bracket to frame (Fig. 1). 3. Using a shallow socket and extension or equivalent, tap with a hammer to drive inner bumper bracket studs out of frame. 4. Separate inner bumper bracket from frame. INSTALLATI0N 1. Position inner bumper bracket studs into frame. 2. Install nuts attaching inner bumper bracket to frame and tighten to 94 N.m (70 ft.lbs.). 3. Install bolts attaching top of bumper to bumper bracket. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair Front Bumper Cover / Fascia: Service and Repair FRONT FASCIA REMOVAL 1. Remove the front bumper. 2. Remove the bolts attaching the fascia to the bumper. 3. Separate fascia from bumper. INSTALLATI0N 1. Position fascia on bumper. 2. Install the bolts attaching the fascia to the bumper. 3. Install the front bumper. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair Rear Bumper Cover / Fascia: Service and Repair REAR FASCIA REMOVAL 1. Remove rivets at each side rear wheel well. NOTE: Removing the step pad will damage the step pad retainers, verify availability of step pad from parts supplier. 2. Using a trim stick C-4755 or equivalent, carefully pry step pad from fascia. 3. Disconnect license plate lamp connector. Fig. 3 4. Remove upper push pin from the bumper fascia (Fig. 3). 5. Remove the lower push pins from the bumper fascia. 6. Remove the bumper fascia from the bumper (Fig. 2). INSTALLATION 1. Position the bumper fascia on the bumper (Fig. 2). 2. Install upper push pin. 3. Align all holes and install the lower push pins. 4. Position step pad on fascia and press into place. 5. Connect license plate lamp connector. 6. Align fascia bracket, wheel house liner shield and fascia holes and install rivets. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL GRILLE AND SCREEN REMOVAL 1. Open hood. 2. Remove the wiper arms. Fig. 4 3. Remove upper plastic nuts attaching cowl grille to cowl (Fig. 4). 4. Insert a small flat blade into the slots of the plastic rivet anchors in each cowl grille corner. Lift up on the flat blade to release the rivet anchors. 5. Remove cowl weatherstrip. 6. Disconnect and plug windshield washer feed line from cowl. 7. Disconnect vacuum line from cowl. 8. Separate cowl grille from cowl. INSTALLATION 1. Position cowl grille on cowl. 2. Connect vacuum line to cowl. 3. Remove the plug and connect windshield washer feed line to cowl. 4. Install cowl weatherstrip. 5. Position rivet anchors in place and press down to engage. 6. Install upper plastic nuts attaching cowl grille to cowl. 7. Install the wiper arms. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair Front Door Exterior Handle: Service and Repair EXTERIOR HANDLE REMOVAL 1. Remove door trim panel. 2. Remove water dam as necessary to gain access to door handle. 3. Roll glass up. Fig. 3 4. Remove fastener access plug from door end panel (Fig. 3). Fig. 4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Page 6571 5. Disengage lock cylinder to latch rod from the latch, if equipped. (Fig. 4) 6. Disengage outside handle to latch rod from the latch. 7. Remove nuts attaching outside door handle to door. 8. Separate outside handle from the door. INSTALLATI0N 1. Position outside handle in the door. 2. Install nuts attaching outside door handle to door and tighten to 5.0 N.m (45 in. lbs). 3. Engage outside handle to latch rod to the latch. 4. Engage lock cylinder to latch rod to the latch, if equipped. 5. Install fastener access plug in the door end panel. 6. Install water dam. 7. Install door trim panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair Front Door Hinge: Service and Repair HINGE REMOVAL 1. Support door on a suitable lifting device. 2. Using a grease pencil or equivalent, mark the outline of the door hinge on the hinge pillar and door end frame to aid installation. 3. Remove bolts attaching hinge to door. 4. Remove bolts attaching door hinge to hinge pillar. 5. Separate door hinge from vehicle. INSTALLATION 1. If necessary, paint replacement door hinge before installation. 2. Position door hinge on hinge pillar using alignment marks. 3. Install bolts attaching door hinge to hinge pillar and tighten to 28 N.m (21 ft.lbs.). 4. Install bolts attaching hinge to door and tighten to 28 N.m (21 ft.lbs.). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Adjustments Front Door Latch: Adjustments ADJUSTMENTS ADJUSTMENT Fig. 7 1. Locate access hole (Fig. 7). 2. Insert a 5/32 inch hex-wrench through hole and into adjustment screw. Loosen screw. 3. Operate outside handle button several times to release any restriction because of misalignment. 4. Tighten adjustment screw to 3 N.m (30 in.lbs.). 5. Test handle button and lock cylinder for proper operation. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Adjustments > Page 6578 Front Door Latch: Service and Repair LATCH REMOVAL 1. Remove door trim panel. 2. Peel back water dam as necessary. 3. For access to latch, roll up glass and remove bolts attaching rearward glass run channel to door. Move and secure glass run channel. Fig. 6 4. Remove screws attaching latch to door shut face (Fig. 6). 5. Disengage wire harness connector for power door locks, if equipped. 6. Disengage lock button to latch rod from the latch. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Adjustments > Page 6579 Fig. 4 7. Disengage lock cylinder to latch rod from the latch (Fig. 4). 8. Disengage inside handle to latch rod from the latch. 9. Disengage outside handle to latch rod from the latch. 10. Separate latch from door. INSTALLATI0N 1. Engage latch rod to outside handle. 2. Engage inside handle to latch rod to the latch. 3. Engage lock cylinder to latch rod to the latch. 4. Engage lock button to latch rod to the latch. 5. Position latch in door. 6. Install screws attaching latch to door shut face and tighten 9.6 N.m (85 in.lbs.). 7. Engage outside handle to latch rod to the latch. 8. Engage wire harness connector for power door locks, if equipped. 9. Install rearward glass run channel. 10. Install water dam. 11. Install door trim panel. 12. Using the access hole in the door shut face, loosen the latch adjustment screw and ensure the outside door handle is flush with door outer panel. Tighten the adjustment screw. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim Panel Front Door Panel: Service and Repair Front Door Trim Panel FRONT DOOR TRIM PANEL REMOVAL 1. Release door latch and open door. 2. Roll window down. Fig. 20 Window Crank Removal Tool 3. Remove window crank, if equipped. Fig. 11 Door Trim Panel Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim Panel > Page 6584 Fig. 12 Trim Panel Screw 4. Remove screws attaching trim panel to door. CAUTION: Do not forcibly pull trim panel from door, damage to trim panel may occur. Fig. 10 Trim Panel Retainer 5. Simultaneously lift upward and outward to release retainer steps from inner door panel. 6. Disengage inside handle linkage rod from inside handle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim Panel > Page 6585 Fig. 14 Speaker And Power Mirror Connector 7. Disconnect speaker harness wire connector. 8. Disengage power mirror wire connector, if equipped (driver's side only). Fig. 15 Power Door Lock / Window Connector 9. Disengage clips attaching power window/lock switch panel to door trim panel. Disengage wire connector from switch panel, if equipped. 10. Separate door trim panel from vehicle. INSTALLATION 1. Position trim panel at door. 2. Engage wire connector for window/lock switch panel, if equipped. 3. Engage power mirror wire connector, if equipped. 4. Connect speaker harness wire connector. 5. Engage inside handle linkage rod to inside handle. 6. Align trim panel retainer steps with inner door panel and slide trim panel into place. 7. Install screws attaching trim panel to door. 8. Install window crank, if equipped. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim Panel > Page 6586 Front Door Panel: Service and Repair Trim Panel TRIM PANEL REMOVAL 1. Roll window down. Fig. 10 2. Remove window crank (Fig. 10), if equipped. Fig. 11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim Panel > Page 6587 Fig. 12 3. Remove screws attaching trim panel to door (Fig. 11) and (Fig. 12). CAUTION: Do not forcibly pull trim panel from door, damage to trim panel may occur. Fig. 13 4. Simultaneously lift upward and outward to release retainer steps from inner door panel (Fig. 13). 5. Disengage inside handle linkage rod from inside handle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim Panel > Page 6588 Fig. 14 6. Disconnect speaker harness wire connector (Fig. 14). 7. Disengage power mirror wire connector, if equipped (driver's side only) (Fig. 14). Fig. 15 8. Disengage clips attaching power window/lock switch panel to door trim panel. Disengage wire connector from switch panel, if equipped (Fig. 15). 9. Separate door trim panel from vehicle. INSTALLATI0N 1. Position trim panel at door. 2. Engage wire connector for window/lock switch panel, if equipped. 3. Engage power mirror wire connector, if equipped. 4. Connect speaker harness wire connector. 5. Engage inside handle linkage rod to inside handle. 6. Align trim panel retainer steps with inner door panel and slide trim panel into place. 7. Install screws attaching trim panel to door. 8. Install window crank, if equipped. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim Panel > Page 6589 Front Door Panel: Service and Repair Waterdam WATERDAM REMOVAL 1. Remove the trim panel from the door. Fig. 16 2. Carefully separate the waterdam from the door inner panel at the areas with adhesive (Fig. 16). Remove the waterdam from the door inner panel. INSTALLATI0N 1. Apply an appropriate adhesive/sealant to the waterdam edges before installing it. 2. Position the waterdam on the door inner panel and press it inward at the areas with the adhesive to attach it to the inner panel. 3. Ensure that the retainer step pockets are position correctly in the door inner panel. 4. Install the door trim panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Service and Repair Front Door Striker: Service and Repair LATCH STRIKER REMOVAL 1. Use a wax crayon or equivalent and mark position of striker on B-pillar. Fig. 8 2. Remove bolts attaching striker and shim to B-pillar (Fig. 8). 3. Separate striker from B-pillar. INSTALLATION 1. Using alignment marks, position shim and striker on B-Pillar. 2. Install the bolts tighten to 28 N.m (20 ft.lbs.). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Secondary Seal Front Door Weatherstrip: Service and Repair Front Door Secondary Seal FRONT DOOR SECONDARY SEAL REMOVAL 1. Remove the push-in fasteners attaching the secondary seal to the inner door panel. 2. Separate the secondary seal from the inner door panel. INSTALLATION 1. Position the secondary seal on the inner door panel. 2. Install the push-in fasteners attaching the secondary seal to the inner door panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Secondary Seal > Page 6597 Front Door Weatherstrip: Service and Repair Front Door Weatherstrip FRONT DOOR WEATHERSTRIP REMOVAL 1. Remove A-pillar trim. Refer to Trim Panel. 2. Remove lower cowl trim. 3. Remove door sill trim. 4. Loosen upper and lower B-pillar trim to access weatherstrip. Fig. 3 5. Pull weatherstrip from pinch flange around door opening (Fig. 3). INSTALLATION 1. Clean pinch flange 2. Position the weatherstrip on the pinch flange around door opening and press into place. 3. Press B-pillar trim into place. 4. Install lower cowl trim. 5. Install door sill trim. 6. Install A-pillar trim. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Secondary Seal > Page 6598 Front Door Weatherstrip: Service and Repair Roof Rail Weatherstrip/Retainer ROOF RAIL WEATHERSTRIP/RETAINER REMOVAL 1. Release door latch and open door. 2. The rearward corner of the weatherstrip is adhesively attached to the body. Peel back the corner of the weatherstrip to release it from the body. Fig. 9 3. Pull weatherstrip from retainer (Fig. 9). Fig. 10 4. Remove screws attaching retainer to roof rail (Fig. 10). 5. Separate retainer from vehicle. INSTALLATION NOTE: The screws attaching the retainer to the roof are coated with wax to prevent water leakage. If the retainer has been removed from the roof, replace the screws. 1. Ensure the area where tape secures the weatherstrip is clean. Use Mopar(R) Super Clean or equivalent. 2. Position retainer on vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Secondary Seal > Page 6599 3. Install screws attaching retainer to roof rail. 4. Starting at the forward end of retainer, push weatherstrip on until seated. 5. Peel the backing from the rearward end of the weatherstrip and press to secure. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Inner Belt Weatherstrip Front Door Window Glass Weatherstrip: Service and Repair Front Door Inner Belt Weatherstrip FRONT DOOR INNER BELT WEATHERSTRIP REMOVAL 1. Remove trim panel. Fig. 2 2. Peel seal from door (Fig. 2). INSTALLATION 1. Slide seal into position on door. 2. Install the trim panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Inner Belt Weatherstrip > Page 6605 Front Door Window Glass Weatherstrip: Service and Repair Front Door Outer Belt Weatherstrip FRONT DOOR OUTER BELT WEATHERSTRIP REMOVAL 1. Lower glass. Fig. 2 2. Lift rearward corner of weatherstrip and slide weatherstrip rearward (Fig. 2). INSTALLATION 1. Lightly lubricate weatherstrip with silicone and slide weatherstrip behind mirror. 2. Push weatherstrip down to seat onto door. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Inner Belt Weatherstrip > Page 6606 Front Door Window Glass Weatherstrip: Service and Repair Front Door Glass Run Weatherstrip FRONT DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove glass. Fig. 2 2. Pull the glass run weatherstrip and run channels from the window opening (Fig. 2). 3. Pull the glass run weatherstrip from the run channels. INSTALLATION 1. Install the glass run weatherstrip in the run channels. 2. Install the glass run weatherstrip in the window opening. 3. Position the run channels in the door. 4. Install glass. 5. Install door trim panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Inner Belt Weatherstrip > Page 6607 Front Door Window Glass Weatherstrip: Service and Repair Glass Run Channel GLASS RUN CHANNEL REMOVAL 1. Remove trim panel. 2. Remove water dam as necessary to access lower run channels. Fig. 5 3. Remove bolts attaching lower glass run channels to door panel (Fig. 5). 4. Remove glass. 5. Slide lower run channels downward to disengage from upper run channels. 6. Remove lower run channels from door. INSTALLATI0N 1. Position lower run channels in door. 2. Slide lower run channels upward to engage in to upper run channels. 3. Install glass. 4. Install bolts attaching lower glass run channels to door panel. 5. Install water dam. 6. Install trim panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Procedures Front Door Window Regulator: Procedures FRONT DOOR WINDOW REGULATOR REMOVAL 1. Remove door trim panel. 2. Partially remove waterdam. 3. Position glass to access the fasteners. Remove the fasteners. 4. Disengage glass from regulator lift channel. 5. Position glass up into door frame (rest glass on a block of wood on door reinforcement). 6. Disconnect regulator wire harness. Fig. 38 Front Door Window Regulator Fig. 39 Power Regulator Bolts 7. Remove screws attaching window regulator to door inner panel. 8. Remove window regulator from door. INSTALLATION Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 6612 1. Position window regulator in door. 2. Loosely install screws attaching window regulator to door inner panel. 3. Position glass onto window regulator lift channel. 4. Install glass to lift channel fasteners. 5. Cycle the window glass to the full up position. 6. Tighten bolts attaching lower front glass run channel to door inner panel. 7. Tighten fasteners holding window regulator to door inner panel. 8. Connect regulator wire harness, if equipped. 9. Install waterdam. 10. Install door trim panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 6613 Front Door Window Regulator: Removal and Replacement WINDOW REGULATOR REMOVAL 1. Remove door trim panel. 2. Partially remove waterdam. 3. Position glass to access the fasteners. Remove the fasteners. 4. Disengage glass from regulator lift channel. 5. Position glass up into door frame (rest glass on a block of wood on door reinforcement). 6. Disconnect regulator wire harness. Fig. 17 Fig. 18 7. Remove screws attaching window regulator to door inner panel (Fig. 17) and (Fig. 18). 8. Remove window regulator from door. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 6614 INSTALLATI0N 1. Position window regulator in door. 2. Loosely install screws attaching window regulator to door inner panel. 3. Position glass onto window regulator lift channel. 4. Install glass to lift channel fasteners. 5. Cycle the window glass to the full up position. 6. Tighten bolts attaching lower front glass run channel to door inner panel. 7. Tighten fasteners holding window regulator door inner panel. 8. Connect regulator wire harness, if equipped. 9. Install waterdam. 10. Install door trim panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair Rear Door Exterior Handle: Service and Repair EXTERIOR HANDLE REMOVAL 1. Remove trim panel. 2. Peel back waterdam to access outside handle. 3. Remove glass run channel. Refer to Window Track. Fig. 2 4. Disconnect latch rod (Fig. 2). Fig. 3 5. Remove nuts attaching handle to outer door panel (Fig. 3). 6. Separate outside handle from rear door. INSTALLATION 1. Position outside handle in rear door. 2. Install nuts attaching handle to outer door panel (Fig. 3). 3. Connect latch rod (Fig. 2). 4. Install glass run channel. Refer to Window Track. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Page 6620 5. Install waterdam. 6. Install trim panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair Rear Door Hinge: Service and Repair HINGE REMOVAL 1. Remove B-pillar trim. Refer to Trim Panel. 2. Disconnect door wire harness connector. 3. Support door on suitable stand. 4. Using a grease pencil or equivalent, mark hinge position on B-pillar. Fig. 1 5. Remove bolts attaching hinge to B-pillar (Fig. 1). 6. Separate door from vehicle. 7. Using a grease pencil or equivalent, mark hinge position on door. 8. Remove bolts attaching hinge to door. INSTALLATION 1. Align and position hinge on door. 2. Install bolts attaching hinge to door and tighten to 28 N.m (20 ft.lbs.). 3. Align and position door on vehicle. 4. Install bolts attaching hinge to B-pillar (Fig. 1) and tighten to 28 N.m (20 ft.lbs.). 5. Connect door wire harness connector. 6. Install B-pillar trim. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair Rear Door Latch: Service and Repair LATCH REMOVAL 1. Remove trim panel. 2. Peel waterdam back to access latch. Fig. 5 3. Disconnect latch rods from latch (Fig. 5). 4. Disconnect the latch harness connector. Fig. 6 5. Remove screws attaching latch to rear door (Fig. 6). INSTALLATION 1. Connect the latch harness connector. 2. Install screws attaching latch to rear door. 3. Connect latch rods to latch. 4. Install waterdam. 5. Install trim panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Door Trim Panel Rear Door Panel: Service and Repair Rear Door Trim Panel REAR DOOR TRIM PANEL REMOVAL 1. Release door latch and open door. 2. Roll window down. Fig. 20 Window Crank Removal Tool 3. Remove window crank, if equipped. Fig. 40 Rear Door Trim Panel 4. Remove screws attaching trim panel to door. CAUTION: Do not forcibly pull trim panel from door, damage to trim panel may occur. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Door Trim Panel > Page 6631 Fig. 10 Trim Panel Retainer 5. Simultaneously lift upward and outward to release retainer steps from inner door panel. 6. Disengage inside handle linkage rod from inside handle. Fig. 42 Power Window/Lock Connector 7. Disconnect power window/lock harness connector, if equipped. 8. Separate door trim panel from vehicle. 9. If necessary, pull upper trim extension outward to disengage from rear door. INSTALLATION 1. If removed, install upper trim extension on rear door. 2. Position trim panel at door. 3. Engage harness connector for power window/lock, if equipped. 4. Engage inside handle linkage rod to inside handle. 5. Align trim panel retainer steps with inner door panel and slide trim panel into place. 6. Install screws attaching trim panel to door. 7. Install window crank, if equipped. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Door Trim Panel > Page 6632 Rear Door Panel: Service and Repair Trim Panel TRIM PANEL REMOVAL 1. Roll window down. Fig. 8 2. Remove window crank (Fig. 8), if equipped. Fig. 9 3. Remove screws attaching trim panel to door (Fig. 9). CAUTION: Do not forcibly pull trim panel from door, damage to trim panel may occur. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Door Trim Panel > Page 6633 Fig. 10 4. Simultaneously lift upward and outward to release retainer steps from inner door panel (Fig. 10). 5. Disengage inside handle linkage rod from inside handle. Fig. 11 6. Disconnect power window/lock harness connector, if equipped (Fig. 11). 7. Separate door trim panel from vehicle. 8. If necessary, pull upper trim extension outward to disengage from rear door. INSTALLATI0N 1. If removed, install upper trim extension on rear door. 2. Position trim panel at door. 3. Engage harness connector for power window/lock, if equipped. 4. Engage inside handle linkage rod to inside handle. 5. Align trim panel retainer steps with inner door panel and slide trim panel into place. 6. Install screws attaching trim panel to door. 7. Install window crank, if equipped. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Door Trim Panel > Page 6634 Rear Door Panel: Service and Repair Waterdam WATERDAM REMOVAL 1. Remove door trim panel. 2. Peel the waterdam from the door. 3. Route the latch rods and wire harnesses through the waterdam. Fig. 12 4. Separate the waterdam from the door inner panel (Fig. 12). INSTALLATI0N 1. Route the latch rods and wire harnesses through the waterdam. 2. Position the waterdam on the door, apply adhesive as necessary and press into place. 3. Install door trim panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Service and Repair Rear Door Striker: Service and Repair LATCH STRIKER REMOVAL 1. Using a grease pencil or equivalent, mark position of striker on C-pillar. Fig. 7 2. Remove bolts attaching striker and shim to C-pillar (Fig. 7). 3. Separate striker from C-pillar. INSTALLATION 1. Using alignment marks, position shim and striker on C-Pillar. 2. Install bolts and tighten to 28 N.m (20 ft.lbs.). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > C-Pillar Seal Rear Door Weatherstrip: Service and Repair C-Pillar Seal C-PILLAR SEAL REMOVAL-C-PILLAR SEAL NOTE: The seal is attached to the door with adhesive tape. Fig. 11 1. Peel the seal from the door (Fig. 11). INSTALLATION-C-PILLAR SEAL 1. Clean the contact area with Mopar(R) Super Kleen or equivalent. 2. Remove the carrier for the seal 3. Align the seal on the door and press into place. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > C-Pillar Seal > Page 6642 Rear Door Weatherstrip: Service and Repair Rear Door Secondary Weatherstrip REAR DOOR SECONDARY WEATHERSTRIP REMOVAL Fig. 7 1. Separate the secondary seal from the inner door panel (Fig. 7). INSTALLATION 1. Thoroughly clean the area of old adhesive. Use Mopar(R) Super Kleen or equivalent. 2. Position the secondary seal on the inner door panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > C-Pillar Seal > Page 6643 Rear Door Weatherstrip: Service and Repair Rear Door Weatherstrip REAR DOOR WEATHERSTRIP REMOVAL 1. Remove door sill trim. 2. Loosen upper and lower B-pillar trim to access weatherstrip. 3. Remove C-pillar trim. Refer to Trim Panel. 4. Pull quarter panel trim outward to access weatherstrip. Fig. 8 5. Pull weatherstrip from pinch flange around door opening (Fig. 8). INSTALLATION 1. Clean pinch flange 2. Position the weatherstrip on the pinch flange around door opening and press into place. 3. Reposition quarter panel trim. 4. Install C-pillar trim. 5. Reposition B-pillar trim. 6. Install door sill trim. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > C-Pillar Seal > Page 6644 Rear Door Weatherstrip: Service and Repair Roof Rail Weatherstrip/Retainer ROOF RAIL WEATHERSTRIP/RETAINER REMOVAL 1. Release door latch and open door. 2. The rearward corner of the weatherstrip is adhesively attached to the body. Peel back the corner of the weatherstrip to release it from the body. Fig. 9 3. Pull weatherstrip from retainer (Fig. 9). Fig. 10 4. Remove screws attaching retainer to roof rail (Fig. 10). 5. Separate retainer from vehicle. INSTALLATION NOTE: The screws attaching the retainer to the roof are coated with wax to prevent water leakage. If the retainer has been removed from the roof, replace the screws. 1. Ensure the area where tape secures the weatherstrip is clean. Use Mopar(R) Super Clean or equivalent. 2. Position retainer on vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > C-Pillar Seal > Page 6645 3. Install screws attaching retainer to roof rail. 4. Starting at the forward end of retainer, push weatherstrip on until seated. 5. Peel the backing from the rearward end of the weatherstrip and press to secure. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel Rear Door Window Glass Weatherstrip: Service and Repair Glass Run Channel GLASS RUN CHANNEL REMOVAL 1. Remove waterdam. Refer to Rear Door Panel. Fig. 4 2. Ensure glass is in full up position and supported. Remove bolts attaching the run channels to door inner panel (Fig. 4). 3. Remove speaker, if necessary. 4. Separate run channels from door. INSTALLATION 1. Position run channels in door. 2. Install bolts attaching the run channels to door inner panel (Fig. 4). 3. Install speaker, if necessary. 4. Install waterdam. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 6651 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Inner Belt Weatherstrip REAR DOOR INNER BELT WEATHERSTRIP REMOVAL 1. Remove trim panel. Fig. 6 2. Pull weatherstrip from inner door panel (Fig. 6). INSTALLATION 1. Position weatherstrip on inner door panel (Fig. 6). 2. Press into place. 3. Install trim panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 6652 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Glass Run Weatherstrip REAR DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove trim panel. 2. Remove inner belt weatherstrip. 3. Remove outer beltline weatherstrip. Fig. 5 4. Pull weatherstrip from door frame and divider bar channel (Fig. 5). INSTALLATION 1. Position weatherstrip in door frame and divider bar channel. 2. Install outer beltline weatherstrip. 3. Install inner beltline weatherstrip. 4. Install trim panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 6653 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Outer Belt Weatherstrip REAR DOOR OUTER BELT WEATHERSTRIP REMOVAL 1. Lower glass. Fig. 6 2. Lift corner of weatherstrip upward and remove weatherstrip from outer door panel (Fig. 6). INSTALLATION 1. Position weatherstrip on outer door panel (Fig. 6). 2. Press into place. 3. Raise glass. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Procedures Rear Door Window Regulator: Procedures REAR DOOR WINDOW REGULATOR REMOVAL 1. Remove upper door trim extension panel. 2. Remove door trim panel. 3. Position glass to access the fasteners. Remove the fasteners. 4. Disengage glass from regulator lift channel. 5. Position glass up into door frame (rest glass on a block of wood on door reinforcement). 6. Lower waterdam. 7. Disconnect regulator wire harness, if equipped. Fig. 55 Rear Door Window Regulator - Manual Fig. 56 Rear Door Window Regulator - Power 8. Remove screws attaching window regulator to door inner panel. 9. Remove window regulator from door. INSTALLATION 1. Position window regulator in door. 2. Loosely install screws attaching window regulator to door inner panel. 3. Install glass onto regulator lift channel. Secure fasteners. 4. Connect regulator wire harness, if equipped. 5. Cycle the window glass to the full up position. 6. Tighten bolts attaching the regulator to the inner door panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 6658 7. Install waterdam. 8. Install door trim panel. 9. Install upper door trim extension panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 6659 Rear Door Window Regulator: Removal and Replacement WINDOW REGULATOR REMOVAL 1. Remove upper door trim extension panel. 2. Remove door trim panel. 3. Position glass to access the fasteners. Remove the fasteners. 4. Disengage glass from regulator lift channel. 5. Position glass up into door frame (rest glass on a block of wood on door reinforcement). 6. Lower waterdam. 7. Disconnect regulator wire harness, if equipped. Fig. 13 Fig. 14 8. Remove screws attaching window regulator to door inner panel (Fig. 13) and (Fig. 14). 9. Remove window regulator from door. INSTALLATION 1. Position window regulator in door. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 6660 2. Loosely install screws attaching window regulator to door inner panel. 3. Install glass onto regulator lift channel. Secure fasteners. 4. Connect regulator wire harness, if equipped. 5. Cycle the window glass to the full up position. 6. Tighten bolts attaching the regulator to the inner door panel. 7. Install waterdam. 8. Install door trim panel. 9. Install upper door trim extension panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair Fuel Door: Service and Repair FUEL FILL DOOR REMOVAL 1. Open the fuel filler door. Fig. 6 2. Remove the screws attaching the door to the quarter panel (Fig. 6). 3. Remove the door from the panel. INSTALLATION 1. Position the fuel filler door on the quarter panel with the screw holes aligned. 2. Install the screws attaching the fuel filler door to the quarter panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair Hood Hinge: Service and Repair HINGE REMOVAL 1. Open hood and support the side that requires hinge replacement. 2. Remove cowl grille. 3. Mark all bolt and hinge attachment locations using a grease pencil or equivalent, to provide reference marks for installation. Fig. 1 4. Remove the nuts attaching the hinge to the hood (Fig. 1). 5. Remove the bolts attaching the hinge to the inner fender. 6. Separate hinge from vehicle. INSTALLATION 1. If necessary, paint new hinge before installation. 2. Position the hinge on the vehicle and align all marks. 3. Install the bolts attaching the hinge to the inner fender and tighten the bolts to 28.2 N.m (250 in.lbs.). 4. Install the nuts attaching the hinge to the hood and tighten the nuts to 22.6 N.m (200 in.lbs). 5. Install cowl grille. 6. Remove support and verify hood operation. The hood should be aligned to 5 mm (0.2 in.) gap to the front fenders. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Insulator / Pad > Component Information > Service and Repair Hood Insulator / Pad: Service and Repair SILENCER PAD REMOVAL Fig. 8 1. Open the hood and remove the retainers attaching the silencer pad to the hood (Fig. 8). 2. Remove the silencer pad from the hood. INSTALLATI0N 1. Position the silencer pad on the hood. 2. Install the retainers attaching the silencer pad to the hood. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Adjustments Hood Latch: Adjustments ADJUSTMENTS 1. Open the hood. 2. Loosen the hood latch screws. 3. Move the latch to the correct location and lightly tighten the screws. 4. Close the hood slowly and observe the latching operation. 5. As necessary, adjust the latch position and tighten the screws. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Latch Hood Latch: Service and Repair Latch LATCH REMOVAL 1. Open the hood and using a grease pencil or equivalent, mark latch position for installation alignment. Fig. 4 2. Remove bolts attaching hood latch to radiator closure panel crossmember (Fig. 4). 3. Separate hood latch from crossmember. Fig. 5 4. Disconnect release cable from hood latch (Fig. 5). INSTALLATION 1. Connect release cable to hood latch. 2. Position hood latch on crossmember. Ensure the bottom flange of hood latch (Fig. 5) is secured around the latch bracket (Fig. 4). 3. Install the bolts attaching hood latch to radiator closure panel crossmember and tighten to 10.7 N.m (80 in.lbs.). 4. Close hood and adjust latch as necessary. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Latch > Page 6676 Hood Latch: Service and Repair Safety Latch SAFETY LATCH REMOVAL Fig. 7 1. Open the hood and remove bolts attaching hood safety latch to hood (Fig. 7). 2. Separate safety latch from hood. INSTALLATION 1. Position safety latch on hood. 2. Install bolts attaching safety latch to hood and tighten to 9.6 N.m (85 in.lbs.). 3. Close hood and verify operation. Adjust as necessary. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release > Component Information > Service and Repair Hood Latch Release: Service and Repair INSIDE HOOD RELEASE BRACKET WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the steering column opening cover from the instrument panel. Fig. 10 3. Remove the two screws that secure the inside hood release handle to the inside hood release bracket and lower the release handle to the floor (Fig. 10). 4. Depress the latch tabs that secure the 16-way data link connector to the inside hood release bracket, and push the connector out of its mounting hole. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release > Component Information > Service and Repair > Page 6680 Fig. 11 5. Remove the two screws that secure the inside hood release bracket to the instrument panel structural support (Fig. 11). 6. Remove the inside hood release bracket from the instrument panel structural support. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the inside hood release bracket onto the instrument panel structural support (Fig. 11). 2. Install the two screws that secure the inside hood release bracket to the instrument panel structural support. 3. Install the 16-way data link connector into the mounting hole on the inside hood release bracket. 4. Position the inside hood release handle to the instrument panel lower reinforcement. 5. Install the two screws that secure the inside hood release handle to the inside hood release bracket. 6. Install the steering column opening cover onto the instrument panel. 7. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair Hood Latch Release Cable: Service and Repair LATCH RELEASE CABLE REMOVAL 1. Remove hood latch. 2. Detach the release cable and the retainer clips in the engine compartment. 3. Separate the release cable grommet from the dash panel hole. Fig. 6 4. From the inside of the vehicle, remove the screws attaching the hood release handle to the bottom of the instrument panel (Fig. 6). 5. Pull/route the hood release cable through the dash panel hole and remove it via the inside of the vehicle. INSTALLATI0N NOTE: If replacement hood latch is also being installed, ensure that it is thoroughly lubricated. 1. From inside the vehicle, pull/route the hood release cable through the dash panel hole and into the engine compartment. 2. Install the hood release handle. 3. Install the cable grommet in the dash panel hole. 4. Attach the retainer clips to the release cable and install them into the holes in the engine compartment. 5. Attach release cable to hood latch. 6. Install hood latch. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Striker > Component Information > Description and Operation Hood Striker: Description and Operation LATCH STRIKER DESCRIPTION The hood latch striker is incorporated with the hood safety latch. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Striker > Component Information > Description and Operation > Page 6687 Hood Striker: Adjustments ADJUSTMENTS 1. Open the hood. 2. Loosen the latch striker screws. 3. Slowly close the hood and observe the latching operation. As necessary, adjust the striker position. Tighten the screws. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Weatherstrip > Component Information > Service and Repair > Hood Seal Hood Weatherstrip: Service and Repair Hood Seal HOOD SEAL REMOVAL Fig. 2 1. Remove push-in fasteners attaching hood seal to inner hood panel (Fig. 2). 2. Separate hood seal from vehicle. INSTALLATI0N 1. Position hood seal on inner hood panel. 2. Install push-in fasteners attaching hood seal to inner hood panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Weatherstrip > Component Information > Service and Repair > Hood Seal > Page 6692 Hood Weatherstrip: Service and Repair Cowl Weatherstrip COWL WEATHERSTRIP REMOVAL Fig. 1 1. Grasp cowl seal and pull seal from flange (Fig. 1). 2. Separate cowl seal from vehicle. INSTALLATION 1. Position cowl seal on flange and press into place. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair Liftgate Window Glass: Service and Repair BACKLITE REMOVAL 1. Remove liftgate upper trim panel. 2. Remove center high mounted stop lamp. 3. Remove rear window wiper arm, if equipped. 4. Remove side moldings. 5. Cut urethane bonding from around liftgate backlite using a suitable sharp cold knife. A pneumatic cutting device can be used if available. 6. Separate backlite from vehicle. INSTALLATION CAUTION: Open a window before installing backlite. This will avoid pressurizing the passenger compartment. If a door is slammed before urethane is cured, water leaks can result. The window opening fence should be cleaned of old urethane bonding material. 1. Clean inside of backlite with Mopar(R) Glass Cleaner or equivalent and lint-free cloth. 2. Apply PVC (vinyl) primer 25 mm (1 in.) wide around edge of backlite. Wipe with clean/dry lint-free cloth. 3. Apply fence primer around edge of fence. Allow at least eighteen minutes drying time. Fig. 8 4. Install new upper and lower seals on liftgate backlite (Fig. 8). 5. Apply a 12 mm (0.4 in.) bead of urethane around window opening fence. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Page 6697 Fig. 9 6. Position backlite into window opening (Fig. 9). 7. Install the side moldings. 8. Install the rear wiper arm, if equipped. 9. Install the center high mounted stop lamp. 10. Install the liftgate upper trim panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Diagrams Liftgate Power Lock Motor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge > Component Information > Service and Repair Trunk / Liftgate Hinge: Service and Repair HINGE REMOVAL 1. Remove liftgate upper trim. 2. Remove D-pillar trim. Refer to Trim Panel. 3. Support liftgate on a suitable lifting device. 4. Using a wax crayon or equivalent, mark the position of the hinge on the liftgate and roof panel. 5. Remove liftgate support cylinder from liftgate. 6. Remove bolts attaching hinge to liftgate. Fig. 2 7. Carefully pull headliner down and remove bolts attaching liftgate hinge to roof panel (Fig. 2). 8. Remove hinge from vehicle. INSTALLATION 1. If necessary, paint replacement hinge before installation. 2. Position hinge on liftgate. 3. Align hinge to marks on liftgate. 4. Install bolts attaching hinge to liftgate. NOTE: Apply 3M-Drip Check Sealant (or an equivalent product) to hinge bolt threads. 5. Align hinge to marks on roof. 6. Install bolts attaching hinge to roof panel. 7. Install liftgate support cylinder to liftgate. 8. Remove support from liftgate. 9. Install D-pillar trim. 10. Install liftgate upper trim. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Service and Repair Trunk / Liftgate Handle: Service and Repair EXTERIOR HANDLE REMOVAL 1. Remove liftgate trim panels. 2. Disconnect liftgate lamp harness connector. 3. Position aside the liftgate watershield to expose liftgate handle. 4. Disconnect vehicle security harness connector, if equipped. 5. Disconnect latch rod and actuator rod. Fig. 1 6. Remove nuts attaching outside handle to liftgate (Fig. 1). 7. Separate outside handle from liftgate. INSTALLATION 1. Position outside handle on liftgate. 2. Install nuts attaching outside handle to liftgate. 3. Connect latch rod and actuator rod. 4. Connect vehicle security harness connector, if equipped. 5. Install liftgate watershield. 6. Connect liftgate lamp harness connector. 7. Install liftgate trim panels. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim Panel > Component Information > Service and Repair > Trim Panel Trunk / Liftgate Interior Trim Panel: Service and Repair Trim Panel TRIM PANEL REMOVAL 1. Pull upper trim outward to disengage spring clips. 2. Separate upper trim from liftgate. Fig. 10 3. Remove screws attaching lower trim to liftgate (Fig. 10). 4. Pull lower trim outward to disengage spring clips. 5. Disconnect liftgate lamp wire connector. 6. Separate lower trim from liftgate. INSTALLATI0N 1. Position lower trim at liftgate. 2. Connect liftgate lamp wire connector. 3. Align lower trim on liftgate and press inward to engage spring clips. 4. Install screws attaching lower trim to liftgate (Fig. 10). 5. Position upper trim on liftgate. 6. Align upper trim to liftgate and press inward to engage spring clips. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim Panel > Component Information > Service and Repair > Trim Panel > Page 6711 Trunk / Liftgate Interior Trim Panel: Service and Repair Molding MOLDING REMOVAL Fig. 7 1. Remove screws attaching molding to liftgate (Fig. 7). 2. Separate molding from liftgate. INSTALLATI0N 1. Position molding on liftgate. 2. Install screws attaching molding to liftgate (Fig. 7). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair Trunk / Liftgate Latch: Service and Repair LATCH REMOVAL 1. Remove liftgate trim panels. 2. Disconnect liftgate lamp harness connector. 3. Peel back liftgate latch watershield. 4. Disconnect liftgate to outside handle latch rod. Fig. 3 5. Remove screws attaching latch to liftgate (Fig. 3). 6. Separate latch from liftgate. INSTALLATI0N 1. Position latch in liftgate. 2. Install screws attaching latch to liftgate (Fig. 3) and tighten to 27.8 N.m (20.5 ft.lbs.). 3. Connect liftgate to outside handle latch rod. 4. Install liftgate latch watershield. 5. Connect liftgate lamp harness connector. 6. Install liftgate trim panels. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair LOCK CYLINDER REMOVAL 1. Remove liftgate trim panels 2. Remove liftgate handle. 3. Remove clip retaining lock cylinder in outside handle. 4. Remove the clip retaining actuator link to lock cylinder. Remove actuator link. Fig. 6 5. Separate lock cylinder from handle (Fig. 6). INSTALLATION 1. Position lock cylinder in outside handle (Fig. 6). 2. Install clip retaining lock cylinder in handle. 3. Install actuator link and retaining clip. 4. Install liftgate handle. 5. Install liftgate trim panels. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Service and Repair Trunk / Liftgate Motor: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the inner liftgate panel. (Refer to DECKLID/HATCH/LIFTGATE/TAILGATE/TRIM PANEL - REMOVAL). Fig. 6 Liftgate Power Lock Motor Remove/Install 3. Remove the two screws that secure the power lock motor to the liftgate inner panel. 4. Pull the power lock motor out through the access hole in the liftgate inner panel far enough to access and disconnect the liftgate power lock motor pigtail wire connector from the liftgate wire harness connector. 5. Lower the power lock motor far enough to access and disengage the link from the liftgate latch link clip. 6. Remove the power lock motor from the liftgate. INSTALLATION 1. Position the liftgate power lock motor into the liftgate through the access hole in the liftgate inner panel. 2. Insert the liftgate power lock motor link into the liftgate latch link clip and snap the clip over the link. 3. Reconnect the liftgate power lock motor pigtail wire connector to the liftgate wire harness connector. 4. Position the liftgate power lock motor to the liftgate inner panel. 5. Install and tighten the two screws that secure the power lock motor to the liftgate inner panel. Tighten the screws to 3 Nm (30 in. lbs.). 6. Reinstall the trim panel onto the liftgate inner panel. (Refer to DECKLID/HATCH/LIFTGATE/TAILGATE/TRIM PANEL - INSTALLATION). 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Service and Repair Trunk / Liftgate Shock / Support: Service and Repair SUPPORT CYLINDER REMOVAL 1. Support liftgate on a suitable lifting device. Fig. 8 2. Remove bolt attaching liftgate support cylinder to D-pillar (Fig. 8). Fig. 9 3. Remove bolt attaching liftgate support cylinder to liftgate (Fig. 9). 4. Remove liftgate support cylinder from liftgate. INSTALLATION 1. Position liftgate support cylinder on liftgate. 2. Install bolt attaching liftgate support cylinder to liftgate, note top and bottom of support cylinder. 3. Install bolt attaching liftgate support cylinder to D-pillar (Fig. 8) and tighten to 28.2 N.m (250 in.lbs.). 4. Remove lifting device. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Striker > Component Information > Service and Repair Trunk / Liftgate Striker: Service and Repair LATCH STRIKER REMOVAL 1. Remove liftgate trim scuff pad. Fig. 4 2. Remove screws attaching liftgate striker to floor pan (Fig. 4). 3. Separate striker from vehicle. INSTALLATION 1. Position striker on vehicle. 2. Install screws attaching liftgate striker to floor pan (Fig. 4) and tighten to 27.8 N.m (20.5 ft.lbs.). 3. Install liftgate trim scuff pad. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Diagrams Liftgate Ajar Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Diagrams > Page 6730 Trunk / Liftgate Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Diagrams > Page 6731 Trunk / Liftgate Switch: Description and Operation LIFTGATE AJAR SWITCH The liftgate ajar switch is integral to the latch on the liftgate. The switch closes a path to ground for the Central Timer Module (CTM) when the liftgate is opened, and opens the ground path when the liftgate is closed. The liftgate ajar switch cannot be repaired and, if faulty or damaged, the liftgate latch unit must be replaced. The liftgate ajar switch closes a path to ground for the Central Timer Module (CTM) when the liftgate is opened, and opens the ground path when the liftgate is closed. The liftgate ajar switch is connected in series between ground and the CTM to provide a unique input. The CTM reads the switch status through an internal pull-up, then sends the proper switch status messages to other electronic modules over the Programmable Communications Interface (PCI) data bus network. The liftgate ajar switch can be diagnosed using conventional diagnostic tools and methods. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Diagrams > Page 6732 Trunk / Liftgate Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Disconnect the liftgate latch pigtail wire connector from the liftgate wire harness connector. Check for continuity between the ground circuit cavity in the liftgate wire harness connector and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the open ground circuit to ground as required. 2. Check for continuity between the ground circuit cavity and the liftgate ajar switch sense circuit cavity in the liftgate latch pigtail wire connector. There should be continuity with the liftgate opened, and no continuity with the liftgate closed. If OK, go to Step 3. If not OK, replace the faulty liftgate latch unit. 3. Disconnect the body wire harness connector (Connector C2) for the Central Timer Module (CTM) from the CTM connector receptacle. Check for continuity between the liftgate ajar switch sense circuit cavity of the body wire harness connector (Connector C2) and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, repair the shorted liftgate ajar switch sense circuit between the liftgate latch and the CTM as required. 4. Check for continuity between the liftgate ajar switch sense circuit cavities of the body wire harness connector (Connector C2) and the liftgate wire harness connector for the liftgate latch. There should be continuity. If OK, use a DRB III scan tool to diagnose the CTM. Refer to the appropriate diagnostic procedures. If not OK, repair the open liftgate ajar switch sense circuit between the liftgate latch and the CTM as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Weatherstrip > Component Information > Service and Repair Trunk / Liftgate Weatherstrip: Service and Repair LIFTGATE OPENING WEATHERSTRIP REMOVAL 1. Remove liftgate opening upper trim. 2. Remove liftgate opening scuff plate. Fig. 4 3. Pull weatherstrip from liftgate opening (Fig. 4). INSTALLATION 1. Position weatherstrip in liftgate opening and align corners (Fig. 4). 2. Press weatherstrip onto flange and carefully place over quarter panel trim. 3. Connect ends at bottom/center of liftgate opening. 4. Install liftgate opening scuff plate. 5. Install liftgate opening upper trim. 6. Carefully place weatherstrip over trim using a fiber stick. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair Body Emblem: Service and Repair EXTERIOR NAME PLATES REMOVAL NOTE: Exterior nameplates are attached to body panels with adhesive tape. 1. Apply a length of masking tape on the body, parallel to the top edge of the nameplate to use as a guide, if necessary. 2. If temperature is below 21 degrees C (70 degrees F) warm emblem with a heat lamp or gun. Do not exceed 52 degrees C (120 degrees F) when heating emblem. 3. Insert a plastic trim stick or a hard wood wedge behind the emblem to separate the adhesive backing from the body. 4. Clean adhesive residue from body with MOPAR(R) Super Clean solvent or equivalent. INSTALLATI0N 1. Remove carrier from adhesive tape on back of emblem. Fig. 5 2. Position emblem properly on body (Fig. 5). 3. Press emblem firmly to body with palm of hand. 4. If temperature is below 21 degrees C (70 degrees F) warm emblem with a heat lamp or gun to assure adhesion. Do not exceed 52 degrees C (120 degrees F) when heating emblem. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL GRILLE AND SCREEN REMOVAL 1. Open hood. 2. Remove the wiper arms. Fig. 4 3. Remove upper plastic nuts attaching cowl grille to cowl (Fig. 4). 4. Insert a small flat blade into the slots of the plastic rivet anchors in each cowl grille corner. Lift up on the flat blade to release the rivet anchors. 5. Remove cowl weatherstrip. 6. Disconnect and plug windshield washer feed line from cowl. 7. Disconnect vacuum line from cowl. 8. Separate cowl grille from cowl. INSTALLATION 1. Position cowl grille on cowl. 2. Connect vacuum line to cowl. 3. Remove the plug and connect windshield washer feed line to cowl. 4. Install cowl weatherstrip. 5. Position rivet anchors in place and press down to engage. 6. Install upper plastic nuts attaching cowl grille to cowl. 7. Install the wiper arms. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Service and Repair Lower Side Moulding / Trim: Service and Repair BODY SIDE MOLDINGS REMOVAL 1. Apply a length of masking tape on the body, parallel to the top edge of the molding to use as a guide, if necessary. 2. Warm the effected adhesive type molding and body metal to approximately 38 degrees C (100 degrees F) using a suitable heat lamp or heat gun. Fig. 1 3. Pull stick-on molding from painted surface (Fig. 1). INSTALLATION 1. Clean body surface with MOPAR(R) Super Kleen solvent or equivalent. Wipe surface dry with lint free cloth. 2. Remove protective cover from tape on back of molding. Apply molding to body below the masking tape guide. 3. Remove masking tape guide and firmly press molding to body surface to assure adhesion. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair Front Fender Liner: Service and Repair FRONT WHEELHOUSE SPLASH SHIELD REMOVAL 1. Remove the front wheel. 2. Remove wheel opening molding. Fig. 9 3. Remove plastic rivets attaching wheelhouse liner to wheelhouse (Fig. 9). 4. Separate liner from vehicle. INSTALLATI0N 1. Position liner in wheelhouse. 2. Install plastic rivets attaching wheelhouse liner to wheelhouse. 3. Install wheel opening molding. 4. Install the front wheel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Fender > Rear Fender > Rear Fender Liner > System Information > Service and Repair Rear Fender Liner: Service and Repair REAR WHEELHOUSE SPLASH SHIELD REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel. Fig. 11 3. Remove plastic rivets attaching wheelhouse liner to vehicle (Fig. 11). 4. Separate wheelhouse liner from vehicle. INSTALLATION 1. Position wheelhouse liner on vehicle. 2. Align holes and install plastic rivets (Fig. 11). 3. Install the wheel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Transmission Crossmember - Service Precautions Cross-Member: Technical Service Bulletins Transmission Crossmember - Service Precautions NUMBER: 13-002-00 GROUP: Frame And Bumpers DATE: Oct. 27, 2000 SUBJECT: Transmission Crossmember Service MODELS: 2000 - 2001 (AN) Dakota 2000 - 2001 (DN) Durango DISCUSSION: The fasteners that retain the transmission crossmember to the frame utilize a thread lock patch on the threads of the fastener. The thread lock patch is required to help prevent the fastener from loosening during normal vehicle usage. When the transmission crossmember is required to be removed during service, the amount of thread patch material on the fastener will deteriorate during fastener removal. To ensure that the fastener retention is not compromised after service, the transmission crossmember fastener threads must have Mopar Lock & Seal p/n 04318031 added to the threads of each fastener. POLICY: Information Only Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Service and Repair Skid Plate: Service and Repair FUEL TANK SKID PLATE REMOVAL 1. Position a support under skid plate. 2. Remove inboard screws that attach skid plate to crossmember. Fig. 7 3. Remove bolts that attach skid plate to frame side rail (Fig. 7). 4. Remove support and skid plate from vehicle. INSTALLATION 1. Position and support skid plate under fuel tank. 2. Install inboard screws attaching skid plate to crossmember and tighten to 41 N.m (30 ft.lbs.). 3. Install bolts attaching skid plate to frame side rail and tighten to 23 N.m (17 ft.lbs.). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair Trailer Hitch: Service and Repair TRAILER HITCH REMOVAL 1. Remove spare tire. 2. Support trailer hitch on a suitable lifting device. Fig. 8 3. Remove fasteners attaching trailer wiring connector to trailer hitch, if equipped (Fig. 8). Fig. 9 4. Remove bolts attaching trailer hitch to frame rails and rear crossmember (Fig. 9). 5. Separate trailer hitch from vehicle. INSTALLATION 1. Position trailer hitch on vehicle. 2. Install the bolts attaching trailer hitch to frame rail and rear crossmember. Tighten bolts to 108 N.m (80 ft.lbs.) torque. 3. Install fasteners attaching trailer wiring connector to trailer hitch, if equipped. 4. Install spare tire. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair Grille: Service and Repair GRILLE REMOVAL 1. Open hood. 2. Remove screws attaching bottom of grille to grille mounting bracket. Fig. 7 3. Remove nuts attaching grille to hood (Fig. 7). 4. Separate grille from vehicle. INSTALLATION 1. Position grille on hood. 2. Install nuts attaching grille to hood. 3. Install screws attaching bottom of grille to grille mounting bracket. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > Customer Interest for Arm Rest: > 23-006-01 > Apr > 01 > Center Armrest/Console - Binds/Sticks Arm Rest: Customer Interest Center Armrest/Console - Binds/Sticks NUMBER: 23-006-01 GROUP: Body DATE: April 13, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-24-98, DATED JUNE 19, 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 ADDITIONAL MODEL YEARS AND CHANGES TO THE PROCEDURE. SUBJECT: Center Armrest/Console Upper Inertia Latch Cover Broken OVERVIEW: This bulletin involves replacing the center armrest/console upper **and lower** inertia latch cover. MODELS: 1997 - **2001** (AN) Dakota 1998 - **2001** (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH THE 40-20-40 SPLIT BENCH SEAT (SALES CODE CBE). SYMPTOM/CONDITION: The center armrest/console upper inertia latch cover (driver side hinge cover) is broken. DIAGNOSIS: Inspect the center armrest/console upper inertia latch/hinge cover on the driver side of the armrest (Fig. 1) at the rear flange and internal check strap for a cracked or broken condition. If the cover is cracked or broken, the arm rest may bind or stick when raising or lowering the armrest. Additionally, it the cover is broken, the leg of the cover may extend out from the rear of the armrest when the armrest is folded down. If the cover is cracked or broken, perform the Repair Procedure. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > Customer Interest for Arm Rest: > 23-006-01 > Apr > 01 > Center Armrest/Console - Binds/Sticks > Page 6778 PARTS REQUIRED: REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Move the driver seat to the full forward position with the seat back full forward. 2. Place the center armrest/console in the down position. 3. Remove the screw securing the cover to the inertia latch. 4. Remove the upper and lower inertia latch covers. 5. Place the new upper latch cover **p/n 05017734AA**, onto the inertia latch upper arm with the rear strap around the post. Ensure that the check strap loops under the stud on the side of the lower stanchion/post and that the white slip cover is over the stud and under the check strap. 6. Open the lower inertia latch cover **p/n 05016165AB**, and install the cover onto the inertia latch upper arm working it around the latch bracket. 7. Align the lower inertia latch cover, upper inertia latch cover, and latch bracket to the screw hole on the arm. 8. Secure the cover with the screw and tighten the screw to 4.15 Nm (37 in. lbs.). 9. Inspect the inertia latch, covers, and screw for proper alignment. Perform a function check by moving the center armrest/console through its full range of travel checking for freedom of movement. Adjust the center armrest/console inertia latch covers as necessary. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Arm Rest: > 23-006-01 > Apr > 01 > Center Armrest/Console Binds/Sticks Arm Rest: All Technical Service Bulletins Center Armrest/Console - Binds/Sticks NUMBER: 23-006-01 GROUP: Body DATE: April 13, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-24-98, DATED JUNE 19, 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 ADDITIONAL MODEL YEARS AND CHANGES TO THE PROCEDURE. SUBJECT: Center Armrest/Console Upper Inertia Latch Cover Broken OVERVIEW: This bulletin involves replacing the center armrest/console upper **and lower** inertia latch cover. MODELS: 1997 - **2001** (AN) Dakota 1998 - **2001** (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH THE 40-20-40 SPLIT BENCH SEAT (SALES CODE CBE). SYMPTOM/CONDITION: The center armrest/console upper inertia latch cover (driver side hinge cover) is broken. DIAGNOSIS: Inspect the center armrest/console upper inertia latch/hinge cover on the driver side of the armrest (Fig. 1) at the rear flange and internal check strap for a cracked or broken condition. If the cover is cracked or broken, the arm rest may bind or stick when raising or lowering the armrest. Additionally, it the cover is broken, the leg of the cover may extend out from the rear of the armrest when the armrest is folded down. If the cover is cracked or broken, perform the Repair Procedure. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Arm Rest: > 23-006-01 > Apr > 01 > Center Armrest/Console Binds/Sticks > Page 6784 PARTS REQUIRED: REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Move the driver seat to the full forward position with the seat back full forward. 2. Place the center armrest/console in the down position. 3. Remove the screw securing the cover to the inertia latch. 4. Remove the upper and lower inertia latch covers. 5. Place the new upper latch cover **p/n 05017734AA**, onto the inertia latch upper arm with the rear strap around the post. Ensure that the check strap loops under the stud on the side of the lower stanchion/post and that the white slip cover is over the stud and under the check strap. 6. Open the lower inertia latch cover **p/n 05016165AB**, and install the cover onto the inertia latch upper arm working it around the latch bracket. 7. Align the lower inertia latch cover, upper inertia latch cover, and latch bracket to the screw hole on the arm. 8. Secure the cover with the screw and tighten the screw to 4.15 Nm (37 in. lbs.). 9. Inspect the inertia latch, covers, and screw for proper alignment. Perform a function check by moving the center armrest/console through its full range of travel checking for freedom of movement. Adjust the center armrest/console inertia latch covers as necessary. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Center Seat Armrest / Console Arm Rest: Service and Repair Center Seat Armrest / Console CENTER SEAT ARMREST/CONSOLE REMOVAL CAUTION: Mark bolt head position prior to disassembly. Failure to maintain proper track spacing may result in high track efforts. 1. Remove bucket seats. Fig. 5 2. Remove the bolts attaching the center seat to the bucket seat inboard seat tracks (Fig. 5). 3. Route the seat belt buckles through the elastic retaining straps. 4. Separate the center seat/armrest from the bucket seats. INSTALLATION 1. Position the center seat/armrest onto the bucket seat inboard seat tracks. 2. Route the seat belt buckles through the elastic retaining straps. 3. Install the bolts attaching the center seat to the bucket seat inboard tracks and tighten to 24 N.m (17 ft. lbs.). 4. Install bucket seats. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Center Seat Armrest / Console > Page 6787 Arm Rest: Service and Repair Center Armrest Inertia Latch Cover CENTER ARMREST INERTIA LATCH COVER REMOVAL 1. Move the drivers seat position to full forward with seat back full forward. 2. Place center arm rest in the down position. Fig. 6 3. Remove the screw securing the cover to the inertia latch (Fig. 6). 4. Remove the upper and lower inertia latch covers. INSTALLATION 1. Install the upper latch cover onto the upper latch inertia arm. Ensure the check strap loops under the stud on the side of the lower stanchion/post. 2. Install the lower latch cover onto the inertia latch upper arm working it around the latch bracket. 3. Align the lower latch cover, the upper latch cover, and the latch bracket to the screw hole on the arm. 4. Secure the cover with the screw and tighten to 4 N.m (37 in. lbs.). 5. Cycle the armrest through a full range of travel and check for freedom of movement. Adjust the latch covers as necessary. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Service and Repair > Removal and Installation Ash Tray: Service and Repair Removal and Installation ASH RECEIVER REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel from the instrument panel. Fig. 3 Ash Receiver 3. Open the instrument panel ash receiver on the instrument panel lower bezel. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry between the upper edge of the ash receiver housing and the instrument panel lower bezel to disengage the two integral snap features of the housing from the their receptacles in the bezel. 5. Pull the ash receiver and housing unit rearward far enough to access and the instrument panel wire harness connector for the cigar lighter. 6. Disconnect the instrument panel wire harness connector for the cigar lighter from the receptacle on the back of the lighter. 7. Remove the ash receiver and housing unit from the instrument panel lower bezel. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the ash receiver and housing unit to the instrument panel. 2. Reconnect the instrument panel wire harness connector for the cigar lighter to the receptacle on the back of the lighter. 3. Insert the two tabs on the bottom of the ash receiver housing into their receptacles in the instrument panel lower bezel. 4. Align the snap features on the top of the ash receiver housing with their receptacles in the instrument panel lower bezel. 5. Using hand pressure, push firmly upward on the ash receiver housing over each of the two snap feature locations until they are fully engaged in their receptacles. 6. Reinstall the cluster bezel onto the instrument panel. 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Service and Repair > Removal and Installation > Page 6792 Ash Tray: Service and Repair Assembly and Disassembly DISASSEMBLY The push/push latch lever of the ash receiver and housing unit used in this vehicle is serviced individually. Following are the procedures for disassembling this component from the ash receiver and housing unit. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the ash receiver and housing unit from the instrument panel lower bezel. Fig. 4 Ash Receiver Guide / Stop Pins 2. Using hand pressure, spread the ash receiver housing far enough to disengage the guide/stop pins on the ash receiver door from the slot on each side of the housing. Fig. 5 Ash Receiver Disassembly / Assembly 3. Unsnap the two hinges on the bottom of the ash receiver door from the hinge pins on the bottom of the ash receiver housing. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Service and Repair > Removal and Installation > Page 6793 Fig. 6 Push/Push Latch Lever 4. From the top of the ash receiver housing, use a blunt tool to push downward on the pivot of the push/push latch lever to disengage it from the housing. 5. From the inside of the ash receiver housing, disengage the push/push latch lever guide tang from the keyed end of the guide slot in the top of the housing. ASSEMBLY The push/push latch lever of the ash receiver and housing unit used in this vehicle is serviced individually. Following are the procedures for assembling this component to the ash receiver and housing unit. 1. From the inside of the ash receiver housing, engage the push/push latch lever guide tang into the keyed end of the guide slot in the top of the housing. 2. From the inside of the ash receiver housing, align the push/push latch lever pivot pin with the pivot hole in the top of the ash receiver housing. 3. Using hand pressure, push firmly over the pivot pin until it snaps into the pivot hole in the top of the ash receiver housing. Fig. 7 Ash Receiver Hinge 4. Align the hinges on the bottom of the ash receiver door with the hinge pins on the bottom of the housing. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Service and Repair > Removal and Installation > Page 6794 THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 5. Using hand pressure, snap the hinges of the ash receiver door onto the hinge pins of the housing. CAUTION: Be certain that the free end of the push/push latch spring on the ash receiver door is inserted into the slotted hole in the ash receiver housing to the left of the push/push latch lever before completing the following step or the spring may be damaged. 6. Using hand pressure, spread the ash receiver housing far enough to engage the guide/stop pins on the ash receiver door into the slot on each side of the housing. 7. Check the operation of the push/push latch of the ash receiver. 8. Reinstall the ash receiver into the instrument panel lower bezel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Front Carpet Carpet: Service and Repair Front Carpet FRONT CARPET REMOVAL 1. Remove floor console. 2. Remove front seats. 3. Remove 2nd row seats. 4. Remove 3rd row seats, if equipped. 5. Remove front and rear door sill trim. 6. Remove lower left and right cowl trim. 7. Remove left and right B-pillar trim. Refer to Trim Panel. 8. Remove left and right quarter panel trim. 9. Loosen gas pedal bracket. 10. Remove rear fresh air vent. 11. Route wiring through carpet. Fig. 3 12. Remove carpet from vehicle (Fig. 3). INSTALLATION 1. Position carpet in vehicle and align all holes. 2. Route all wire harnesses through openings in carpet. 3. Install front and rear door sill trim. 4. Install quarter panel trim. 5. Install B-pillar trim. Refer to Trim Panel. 6. Install lower cowl trim. 7. Tighten gas pedal bracket. 8. Install 3rd row seats, if equipped. 9. Install 2nd row seats. 10. Install rear fresh air vent. 11. Install front seats. 12. Install floor console. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Front Carpet > Page 6799 Carpet: Service and Repair Rear Carpet REAR CARPET REMOVAL 1. Remove 3rd row seats, if equipped. 2. Remove 3rd row seat belt/buckles, if equipped. 3. Remove left and right quarter panel trim. 4. Remove liftgate scuff plate. 5. Remove screws attaching cargo compartment lid hinge to floor. Fig. 4 6. Remove carpet from vehicle (Fig. 4). INSTALLATION 1. Position carpet in vehicle and align all holes. 2. Install screws attaching cargo compartment lid hinge to floor. 3. Install liftgate scuff plate. 4. Install quarter panel trim. 5. Install 3rd row seat belt/buckles, if equipped. 6. Install 3rd row seats, if equipped. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams Center Console Lamp Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 6808 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Application and ID Glove Compartment: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Glove Compartment ............................................................................................................................ .................................................................... 194 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Removal and Replacement Glove Compartment: Removal and Replacement Glove Box GLOVE BOX ASSEMBLY REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel from the instrument panel. 3. Remove the lower bezel from the instrument panel. 4. Remove the screw that secures the inboard side of the glove box module to the instrument panel behind the lower bezel. 5. Remove the passenger side end cap from the instrument panel. 6. Remove the screw that secures the outboard end of the glove box module to the right end of the instrument panel behind the passenger side end cap. Fig. 5 7. Remove the four screws that secure the bottom of the glove box module to the instrument panel (Fig. 5). 8. Unlatch and open the glove box. 9. Remove the latch striker from the upper glove box opening reinforcement. 10. Remove the two remaining screws that secure the top of the glove box module to the upper glove box opening reinforcement. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Removal and Replacement > Page 6814 Fig. 6 11. If the vehicle is equipped with a glove box lamp, pull the glove box module away from the instrument panel far enough to access and disconnect the instrument panel wire harness connector from the glove box lamp and switch connector receptacle (Fig. 6). 12. Remove the glove box module from the instrument panel. DISASSEMBLY The glove box latch and handle unit of the glove box used in this vehicle are serviced individually. The following is the procedure for disassembling this component. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the glove box door from the glove box module. 2. Remove the nine screws that secure the flanges around the perimeter of the glove box bin to the inside of the glove box door. Fig. 7 3. Remove the glove box bin from the inside of the glove box door (Fig. 7). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Removal and Replacement > Page 6815 NOTE: Dakota shown, Durango similar. 4. Remove the two screws that secure the glove box latch and handle to the inside of the glove box door. 5. Remove the glove box latch and handle from the inside of the glove box door. ASSEMBLY The glove box latch and handle unit of the glove box used in this vehicle is serviced individually. Following are the procedures for assembling this component to the glove box module. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the glove box latch and handle to the inside of the glove box door. 2. Install the two screws that secure the glove box latch and handle to the inside of the glove box door. 3. Position the glove box bin to the inside of the glove box door (Fig. 7). 4. Install the nine screws that secure the flanges around the perimeter of the glove box bin to the inside of the glove box door. 5. Install the glove box door. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the glove box module to the instrument panel. 2. If the vehicle is equipped with a glove box lamp, reconnect the instrument panel wire harness connector to the glove box lamp and switch connector receptacle (Fig. 6). 3. Position the top of the glove box module to the upper glove box opening reinforcement. 4. Install the two outboard screws that secure the top of the glove box module to the upper glove box opening reinforcement (Fig. 5). 5. Install the glove box latch striker to the upper glove box opening reinforcement. 6. Close and latch the glove box. 7. Install the four screws that secure the bottom of the glove box module to the instrument panel (Fig. 5). 8. Install the screw that secures the outboard end of the glove box module to the right end of the instrument panel behind the passenger side end cap. 9. Install the passenger side end cap onto the instrument panel. 10. Install the screw that secures the inboard side of the glove box module to the instrument panel behind the lower bezel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Removal and Replacement > Page 6816 Fig. 8 11. Open and close the glove box to check for proper hinge operation and alignment (Fig. 8). 12. Install the lower bezel onto the instrument panel. 13. Install the cluster bezel onto the instrument panel. 14. Connect the battery negative cable. Glove Box Latch Striker Replacement GLOVE BOX LATCH STRIKER REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Unlatch and open the glove box. Fig. 9 3. Remove the two screws that secure the latch striker to the upper glove box opening reinforcement (Fig. 9). 4. Remove the latch striker from the upper glove box opening reinforcement. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the latch striker onto the upper glove box opening reinforcement (Fig. 9). 2. Install the two screws that secure the latch striker to the upper glove box opening reinforcement. 3. Close and latch the glove box and check fit. 4. Adjust the striker, if required. 5. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Removal and Replacement > Page 6817 Glove Compartment: Overhaul DISASSEMBLY The glove box latch and handle unit of the glove box used in this vehicle is serviced individually. Following are the procedures for disassembling this component from the glove box module. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the glove box module from the instrument panel. See: 2. Remove the nine screws that secure the flanges around the perimeter of the glove box bin to the inside of the glove box door. Fig. 14 Glove Box Latch & Handle 3. Remove the glove box bin from the inside of the glove box door (Fig. 7). NOTE: Dakota shown, Durango similar. 4. Remove the two screws that secure the glove box latch and handle to the inside of the glove box door. 5. Remove the glove box latch and handle from the inside of the glove box door. ASSEMBLY The glove box latch and handle unit of the glove box used in this vehicle is serviced individually. Following are the procedures for assembling this component to the glove box module. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the glove box latch and handle to the inside of the glove box door. 2. Install and tighten the two screws that secure the glove box latch and handle to the inside of the glove box door. Tighten the screws to 2 Nm (20 in.lbs). 3. Position the glove box bin to the inside of the glove box door (Fig. 7). 4. Install and tighten the nine screws that secure the flanges around the perimeter of the glove box bin to the inside of the glove box door. Tighten the screws to 2 Nm (20 in.lbs). 5. Reinstall the glove box module onto the instrument panel. See: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair Headliner: Service and Repair HEADLINER REMOVAL 1. Disconnect battery negative cable. 2. Remove sunvisors and sunvisor arm supports. 3. Remove coat hooks. 4. Remove overhead assist handle. 5. Remove dome lamp. 6. Remove overhead console, if equipped. 7. Remove outlet bezel for rear air conditioner, if equipped. 8. Remove blower control switch for rear air conditioner, if equipped. 9. Remove upper liftgate opening trim. 10. Disengage A-pillar, B-pillar, C-pillar, and D-pillar trim as necessary to prevent trim panel interference. 11. Move 2nd row seats to cargo position. 12. Move front seats to full recline position. 13. Move 3rd row seat to cargo position, if equipped. Fig. 16 14. Remove push-in fasteners attaching headliner to roof panel (Fig. 16). Fig. 15 15. Carefully bow headliner and remove through the liftgate opening (Fig. 15). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 6821 INSTALLATION 1. Carefully bow headliner and slide through the liftgate opening (Fig. 15). 2. Install push-in fasteners attaching headliner to roof panel (Fig. 16). 3. Engage A-pillar, B-pillar, C-pillar, and D-pillar trim. Refer to Trim Panel. 4. Install upper liftgate opening trim. 5. Install blower control switch for rear air conditioner, if equipped. 6. Install outlet bezel for rear air conditioner, if equipped. 7. Install overhead console, if equipped. 8. Install dome lamp. 9. Install overhead assist handle. 10. Install coat hooks. 11. Install sunvisors and sunvisor arm supports. 12. Return seats to seating position. 13. Connect battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Passenger Assist Handle > Component Information > Service and Repair Passenger Assist Handle: Service and Repair A-PILLAR GRAB HANDLE REMOVAL 1. Using a small flat blade screw driver, pry trim plugs from A-pillar grab handle. 2. Remove screws attaching grab handle to A-pillar. 3. Separate A-pillar grab handle from vehicle. INSTALLATION 1. Position grab handle on A-pillar. 2. Install screws attaching grab handle to A-pillar. 3. Install trim plugs in A-pillar grab handle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Service and Repair Scuff Plate: Service and Repair LIFTGATE SCUFF PLATE REMOVAL Fig. 18 1. Remove screws attaching cargo tie downs to liftgate scuff plate (Fig. 18). 2. Grasp scuff plate and lift upward to disengage spring clips. 3. Separate scuff plate from liftgate opening. INSTALLATION 1. Position scuff plate in liftgate opening. 2. Press scuff plate to engage spring clips. 3. Install screws attaching cargo tie downs to liftgate scuff plate (Fig. 18). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair Sun Visor: Service and Repair SUN VISOR REMOVAL NOTE: All vehicles with driver and passenger side airbags must have a color-coded, 5-bullet point air-bag warning label applied to the sunvisor face surface (in the stored position). When replacing the sunvisor, verify label availability and ensure the label is installed. Fig. 21 1. Remove the screws that attach the sunvisor arm support bracket to the headliner and the roof panel (Fig. 21). 2. Disengage vanity lamp connector, if equipped. 3. Detach the sunvisor from the visor supports. 4. Remove the sunvisor from the headliner and roof panel. Fig. 22 5. If necessary, grasp both sides of the visor support base and firmly pull outward to disengage the visor support cover from the base (Fig. 22). 6. Lift/rock the visor support upward to disengage it from the roof panel. INSTALLATION 1. If removed, position visor support in roof panel. 2. Push the visor support cover inward and secure the visor support to the roof panel. 3. Position the sunvisor in the visor supports and align the arm support bracket holes with the headliner holes. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Page 6831 4. Engage vanity lamp connector, if equipped. 5. Install the screws that attach the sunvisor arm support bracket to the headliner and the roof panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures Trim Panel: Procedures STANDARD PROCEDURE - HEAT STAKING 1. Remove trim panel. 2. Bend or move the trim panel components at the heat staked joints. Observe the heat staked locations and/or component seams for looseness. 3. Heat stake the components. a. If the heat staked or component seam location is loose, hold the two components tightly together and using a soldering gun with a flat tip, melt the material securing the components together. Do not over heat the affected area, damage to the exterior of the trim panel may occur. b. If the heat staked material is broken or missing, use a hot glue gun to apply new material to the area to be repaired. The panels that are being heat staked must be held together while the applying the glue. Once the new material is in place, it may be necessary to use a soldering gun to melt the newly applied material. Do not over heat the affected area, damage to the exterior of the trim panel may occur. 4. Allow the repaired area to cool and verify the repair. 5. Install trim panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6836 Trim Panel: Removal and Replacement Cowl Trim COWL TRIM COVER REMOVAL 1. Using a trim stick C-4755 or equivalent, pry cowl trim cover from cowl to disengage clips. 2. Separate cowl trim cover from vehicle. INSTALLATION 1. Position cowl trim cover on cowl. 2. Press cowl trim cover into place to engage clips. Door Sill Trim Panel DOOR SILL TRIM REMOVAL 1. Using a trim stick C-4755 or equivalent, pry up door sill trim. 2. Grasp door sill trim and lift upward. Fig. 8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6837 Fig. 9 3. Separate door sill trim from vehicle (Fig. 8) and (Fig. 9). INSTALLATION 1. Position door sill trim on door sill. 2. Press into place. Front Door Trim Panel FRONT DOOR TRIM PANEL REMOVAL 1. Release door latch and open door. 2. Roll window down. Fig. 20 Window Crank Removal Tool 3. Remove window crank, if equipped. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6838 Fig.19 Door Trim Panel Fig. 22 Trim Panel Screw 4. Remove screws attaching trim panel to door. CAUTION: Do not forcibly pull trim panel from door, damage to trim panel may occur. Fig. 10 Trim Panel Retainer Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6839 5. Simultaneously lift upward and outward to release retainer steps from inner door panel. 6. Disengage inside handle linkage rod from inside handle. Fig. 24 Speaker And Power Mirror Connector 7. Disconnect speaker harness wire connector. 8. Disengage power mirror wire connector, if equipped (driver's side only). Fig. 25 Power Door Lock/Window Connector 9. Disengage clips attaching power window/lock switch panel to door trim panel. Disengage wire connector from switch panel, if equipped. 10. Separate door trim panel from vehicle. INSTALLATION 1. Position trim panel at door. 2. Engage wire connector for window/lock switch panel, if equipped. 3. Engage power mirror wire connector, if equipped. 4. Connect speaker harness wire connector. 5. Engage inside handle linkage rod to inside handle. 6. Align trim panel retainer steps with inner door panel and slide trim panel into place. 7. Install screws attaching trim panel to door. 8. Install window crank, if equipped. Liftgate Opening Upper Trim LIFTGATE OPENING UPPER TRIM Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6840 REMOVAL 1. Using a trim stick C-4755 or equivalent, pry upper trim from liftgate opening. 2. Grasp upper trim and pull downward to disengage spring clips. Fig. 17 3. Separate upper trim from liftgate opening (Fig. 17). INSTALLATION 1. Position upper trim in liftgate opening (Fig. 17). 2. Align spring clips and press inward to secure. Liftgate Sill Scuff Plate Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6841 REMOVAL 1. Remove screws attaching cargo tie downs to liftgate scuff plate. 2. Grasp scuff plate and lift upward to disengage spring clips. 3. Separate scuff plate from liftgate opening. INSTALLATION 1. Position scuff plate in liftgate opening. 2. Press scuff plate to engage spring clips. 3. Install screws attaching cargo tie downs to liftgate scuff plate. A-Pillar Trim A-PILLAR TRIM REMOVAL 1. Remove A-pillar grab handle, if equipped. 2. Remove screws from cowl trim cover. 3. Remove cowl trim cover. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6842 Fig. 1 4. Grasp A-pillar trim and pull outward to disengage clips attaching A-pillar trim to A-pillar (Fig. 1). 5. Separate A-pillar trim from vehicle. INSTALLATION 1. Position A-pillar trim at A-pillar, align clips and press into place. 2. Install cowl trim cover. 3. Install A-pillar grab handle, if equipped. A-Pillar Grab Handle A-PILLAR GRAB HANDLE REMOVAL 1. Using a small flat blade screw driver, pry trim plugs from A-pillar grab handle. 2. Remove screws attaching grab handle to A-pillar. 3. Separate A-pillar grab handle from vehicle. INSTALLATION 1. Position grab handle on A-pillar. 2. Install screws attaching grab handle to A-pillar. 3. Install trim plugs in A-pillar grab handle. B-Pillar Trim B-PILLAR TRIM REMOVAL Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6843 Fig. 2 The upper B-pillar trim is attached to the B-pillar with spring clip retainers. The lower B-pillar trim is attached with screws and spring clip retainers (Fig. 2). 1. Remove front seat belt turning loop cover and turning loop. 2. Grasp upper B-pillar trim and pull outward to release spring clip retainers. 3. Remove door sill trim front and rear. 4. Remove lower B-pillar trim screws. 5. Grasp lower B-pillar trim and pull outward to release spring clip retainers. 6. Route shoulder belt through access slot in lower B-pillar trim. 7. Separate lower B-pillar trim from vehicle. INSTALLATION 1. Position lower B-pillar trim on vehicle. 2. Route shoulder belt through access slot in lower B-pillar trim. 3. Press lower B-pillar trim inward to engage spring clip retainers. 4. Position upper B-pillar trim on vehicle. 5. Press upper B-pillar trim inward to engage spring clip retainers. 6. Install B-pillar trim screws. 7. Install door sill trim front and rear. 8. Install front seat belt turning loop, and tighten bolt to 39 N.m (29 ft. lbs.). 9. Install turning loop cover. C-Pillar Trim C-PILLAR TRIM REMOVAL 1. Remove cover and bolt attaching 2nd row seat belt turning loop to C-pillar. 2. Grasp C-pillar trim and pull outward to disengage spring clips. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6844 Fig. 7 3. Separate C-pillar trim from C-pillar (Fig. 7). INSTALLATION 1. Position C-pillar trim on C-pillar (Fig. 7). 2. Align spring clips and press into place. 3. Install bolt attaching 2nd row seat belt turning loop to C-pillar and tighten to 39 N.m (29 ft. lbs.). 4. Install turning loop cover. D-Pillar Trim D-PILLAR TRIM REMOVAL 1. Remove liftgate opening upper trim. 2. Remove screw attaching D-pillar trim to upper liftgate opening. 3. Remove 3rd row seat, if equipped. 4. Remove nut attaching 3rd row seat belt anchor to quarter panel, if equipped. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6845 Fig. 10 5. Remove bolt attaching 3rd row seat belt turning loop to D-pillar, if equipped (Fig. 10). 6. Remove two screws secureing D-pillar trim to D-pillar. 7. Grasp upper edge of D-pillar trim and carefully pull outward to disengage upper spring clips. 8. Lift D-pillar trim upward to release it from the quarter panel trim. 9. Route 3rd row seat belt through access slot, if equipped. 10. Separate D-pillar trim from vehicle. INSTALLATION 1. Route 3rd row seat belt through access slot, if equipped. 2. Position D-pillar trim on D-pillar. 3. Slid D-pillar trim downward to engage it with the quarter panel trim. 4. Align D-pillar trim upper spring clips and press inward to engage. 5. Install screws attaching D-pillar trim to upper liftgate opening. 6. Install liftgate opening upper trim. 7. Install bolt attaching 3rd row seat belt turning loop to D-pillar, if equipped (Fig. 10) and tighten to 39 N.m (29 ft. lbs.). 8. Install nut attaching 3rd row seat belt anchor to quarter panel, if equipped, and tighten to 39 N.m (29 ft. lbs.). 9. Install 3rd row seat, if equipped. Quarter Panel Trim QUARTER PANEL TRIM REMOVAL 1. Tumble 2nd row seats to cargo position. 2. Remove 3rd row seat, if equipped. 3. Remove C-pillar trim. Refer to Trim Panel. 4. Remove D-pillar trim. Refer to Trim Panel. 5. Remove liftgate opening scuff pad. 6. Remove screws attaching quarter panel trim to C-pillar and D-pillar. 7. Route 2nd row seat belt through access slot in quarter panel trim. 8. Grasp quarter panel trim and pull outward to disengage spring clips. 9. Separate quarter panel trim from vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6846 INSTALLATION 1. Position quarter panel trim in vehicle. 2. Route 2nd row seat belt through access slot in quarter panel trim. 3. Align quarter panel trim spring clips and press inward to engage. 4. Install screws attaching quarter panel trim to C-pillar and D-pillar. 5. Install D-pillar trim. 6. Install C-pillar trim. 7. Install liftgate opening scuff pad. 8. Install 3rd row seat, if equipped. 9. Return 2nd row seats to seating position. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Component Information > Service and Repair > Rear Storage Box Utility Storage Compartment: Service and Repair Rear Storage Box REAR STORAGE BOX REMOVAL FLOOR CARGO STORAGE DOOR THIRD ROW SEAT EQUIPPED The floor cargo storage door is attached to the cargo area carpet. NON-THIRD ROW SEAT EQUIPPED 1. Fold rear seat forward. Fig. 19 2. Remove the four bolts and remove the storage box (Fig. 19). INSTALLATION THIRD ROW SEAT EQUIPPED The floor cargo storage door is attached to the cargo area carpet. NON-THIRD ROW SEAT EQUIPPED 1. Install the storage box. 2. Install the bolts and tighten to 3 N.m (25 in. lbs.). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Component Information > Service and Repair > Rear Storage Box > Page 6851 Utility Storage Compartment: Service and Repair Storage Bin STORAGE BIN REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel from the instrument panel. Fig. 16 3. Remove the three screws that secure the storage bin to the back of the cluster bezel (Fig. 16). 4. Remove the storage bin from the back of the cluster bezel. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the storage bin onto the back of the cluster bezel (Fig. 16). 2. Install and tighten the three screws that secure the storage bin to the back of the cluster bezel. Tighten the screws to 2 N.m (20 in. lbs.). 3. Reinstall the cluster bezel onto the instrument panel. 4. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Door Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks Intermittently Lock/Unlock by Themselves Door Lock Cylinder: Customer Interest Power Locks - Intermittently Lock/Unlock by Themselves NUMBER: 08-023-03 GROUP: Electrical DATE: July 18, 2003 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-041-00, DATED DEC. 15, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THE REVISION ADDS 2002 AND 2003 VEHICLES AND REVISES THE PARTS TABLE. SUBJECT: Intermittent Locking/Unlocking Of Doors Without Activating The Power Door Lock Switch OVERVIEW: This bulletin involves installing new door/liftgate lock cylinder switches. MODELS: **2000 - 2003** (AB) Ram Van/Wagon **2000 - 2003** (AN) Dakota **2000 - 2002** (BR/BE) Ram Truck **2000 - 2003** (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH VEHICLE THEFT SECURITY SYSTEM (SALES CODE LSA). SYMPTOM/CONDITION: The door locks will intermittently lock and/or unlock without any activation of the power door lock switch or a clicking sound may be heard coming from the power door locks (repeated locking or repeated unlocking). The condition may occur more frequently in damp conditions such as driving the vehicle in the rain or taking the vehicle through a car wash. DIAGNOSIS: Vehicles that demonstrate this condition may have water weeping into the door/liftgate lock cylinder switches causing the switch to intermittently short across the internal circuit. This in turn may signal the Central Timer Module (CTM) to activate the power door locks. Because of the nature of this problem, it is extremely difficult to diagnose this condition. Therefore, customers that indicate their doors intermittently lock and unlock without having the door lock switch activated or customers that indicate they hear a repeated clicking noise coming from the door locks should have the Repair Procedure performed on their vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Door Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks Intermittently Lock/Unlock by Themselves > Page 6862 PARTS REQUIRED: NOTE: **The passenger side door lock cylinder switch has been eliminated on 2002 and 2003 Durangos and on 2003 Dakotas built after April 7, 2003 (MDH 0407XX)**. REPAIR PROCEDURE: 1. Remove the driver, passenger (if equipped), and liftgate (Durango only) door lock cylinder switches. Refer to the appropriate Service Manual Group 8Q, pages 8QA and 8Q-5 or the service information available in the MDS2 for DOOR LOCK CYLINDER SWITCH and/or LIFTGATE LOCK CYLINDER SWITCH - REMOVAL AND INSTALLATION procedures. 2. The door lock cylinder switch actuator must be positioned in its neutral position prior to installing the new switch on the lock cylinder. Rotate the actuator until the actuator is positioned as shown in the following figure (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Door Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks Intermittently Lock/Unlock by Themselves > Page 6863 3. Install the driver, passenger (if equipped), and liftgate (Durango only) door lock cylinder switches. Refer to the appropriate Service Manual Group 8Q, pages 8QA and 8Q-5 or the service information available in the MDS2 for DOOR LOCK CYLINDER SWITCH and/or LIFTGATE LOCK CYLINDER SWITCH - REMOVAL AND INSTALLATION procedures. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Door Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks Intermittently Lock/Unlock by Themselves > Page 6864 FAILURE CODE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks Intermittently Lock/Unlock by Themselves Door Lock Cylinder: All Technical Service Bulletins Power Locks - Intermittently Lock/Unlock by Themselves NUMBER: 08-023-03 GROUP: Electrical DATE: July 18, 2003 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-041-00, DATED DEC. 15, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THE REVISION ADDS 2002 AND 2003 VEHICLES AND REVISES THE PARTS TABLE. SUBJECT: Intermittent Locking/Unlocking Of Doors Without Activating The Power Door Lock Switch OVERVIEW: This bulletin involves installing new door/liftgate lock cylinder switches. MODELS: **2000 - 2003** (AB) Ram Van/Wagon **2000 - 2003** (AN) Dakota **2000 - 2002** (BR/BE) Ram Truck **2000 - 2003** (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH VEHICLE THEFT SECURITY SYSTEM (SALES CODE LSA). SYMPTOM/CONDITION: The door locks will intermittently lock and/or unlock without any activation of the power door lock switch or a clicking sound may be heard coming from the power door locks (repeated locking or repeated unlocking). The condition may occur more frequently in damp conditions such as driving the vehicle in the rain or taking the vehicle through a car wash. DIAGNOSIS: Vehicles that demonstrate this condition may have water weeping into the door/liftgate lock cylinder switches causing the switch to intermittently short across the internal circuit. This in turn may signal the Central Timer Module (CTM) to activate the power door locks. Because of the nature of this problem, it is extremely difficult to diagnose this condition. Therefore, customers that indicate their doors intermittently lock and unlock without having the door lock switch activated or customers that indicate they hear a repeated clicking noise coming from the door locks should have the Repair Procedure performed on their vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks Intermittently Lock/Unlock by Themselves > Page 6870 PARTS REQUIRED: NOTE: **The passenger side door lock cylinder switch has been eliminated on 2002 and 2003 Durangos and on 2003 Dakotas built after April 7, 2003 (MDH 0407XX)**. REPAIR PROCEDURE: 1. Remove the driver, passenger (if equipped), and liftgate (Durango only) door lock cylinder switches. Refer to the appropriate Service Manual Group 8Q, pages 8QA and 8Q-5 or the service information available in the MDS2 for DOOR LOCK CYLINDER SWITCH and/or LIFTGATE LOCK CYLINDER SWITCH - REMOVAL AND INSTALLATION procedures. 2. The door lock cylinder switch actuator must be positioned in its neutral position prior to installing the new switch on the lock cylinder. Rotate the actuator until the actuator is positioned as shown in the following figure (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks Intermittently Lock/Unlock by Themselves > Page 6871 3. Install the driver, passenger (if equipped), and liftgate (Durango only) door lock cylinder switches. Refer to the appropriate Service Manual Group 8Q, pages 8QA and 8Q-5 or the service information available in the MDS2 for DOOR LOCK CYLINDER SWITCH and/or LIFTGATE LOCK CYLINDER SWITCH - REMOVAL AND INSTALLATION procedures. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks Intermittently Lock/Unlock by Themselves > Page 6872 FAILURE CODE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Page 6873 Door Lock Cylinder: Service and Repair LOCK CYLINDER REMOVAL 1. Remove door trim panel. 2. Remove outside handle. 3. Disengage lock cylinder to latch rod from the lock cylinder. Fig. 9 4. Using a small flat blade, pry lock cylinder retaining clip from lock cylinder housing/outside handle (Fig. 9). 5. Push lock cylinder out of lock cylinder housing/outside handle. INSTALLATI0N 1. Push lock cylinder into lock cylinder housing/outside handle. Ensure the lock cylinder is fully seated in the handle. 2. Install lock cylinder retaining clip. Ensure the clip is fully seated. 3. Engage lock cylinder to latch rod to the lock cylinder. 4. Install outside handle. 5. Install door trim panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams Door Module: Diagrams Driver Door Module C1 Driver Door Module C2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair Keyless Entry Transmitter Battery: Service and Repair The Remote Keyless Entry (RKE) transmitter case snaps open and shut for battery access. To replace the RKE transmitter batteries: 1. Using a trim stick or a thin coin, gently pry at the notch in the center seam of the RKE transmitter case halves located near the key ring until the two halves unsnap. 2. Lift the back half of the transmitter case off of the RKE transmitter. 3. Remove the two batteries from the RKE transmitter. 4. Replace the two batteries with new Duracell DL2016, or their equivalent. Be certain that the batteries are installed with their polarity correctly oriented. 5. Align the two RKE transmitter case halves with each other, and squeeze them firmly and evenly together using hand pressure until they snap back into place. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams Power Door Lock Actuator: Diagrams Driver Door Power Lock Motor/Ajar Switch Left Rear Door Power Lock Motor/Ajar Switch Passenger Door Power Lock Motor/Ajar Switch Right Rear Door Power Lock Motor/Ajar Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Page 6886 Power Door Lock Actuator: Description and Operation Models equipped with the optional power lock system have a power operated locking mechanism located within each door and the liftgate. The lock mechanisms are actuated by a reversible electric power lock motor. This motor is integral to the door latch unit within each door, but the liftgate lock motor is a separate unit that operates the liftgate latch locking mechanism through a connecting linkage rod. A single short pigtail wire with a molded plastic connector insulator connects each lock motor to the vehicle electrical system through a take out and connector of the wire harness within each door and the liftgate. The power lock motors cannot be adjusted or repaired and, if faulty or damaged, the entire door latch unit or the liftgate lock motor unit must be replaced. The driver side front door power lock motor is controlled by a unique driver unlock relay output of the Central Timer Module (CTM), while the remaining power lock motors are all connected in parallel and share common CTM lock and unlock relay outputs. The driver side front door power lock motor also shares the common lock relay output from the CTM. This circuit arrangement makes the Remote Keyless Entry (RKE) system driver door unlock only feature option possible. A positive and negative battery connection to the two power lock motor terminals will cause the power lock motor plunger to move in one direction. Reversing the current through these same two connections Will cause the power lock motor plunger to move in the opposite direction. The power lock motors and circuits can be tested using conventional diagnostic tools and methods. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Page 6887 Power Door Lock Actuator: Testing and Inspection Before you proceed with this diagnosis, confirm proper power lock switch, Central Timer Module (CTM), and power lock switch output circuit operation. Remember, the CTM circuitry controls the output to each of the power lock motors. 1. Check each power lock motor for correct operation while moving the power lock switch to both the Lock and Unlock positions. If all of the power lock motors are inoperative, go to Step 2. If one power lock motor is inoperative, go to Step 3. 2. If all of the power lock motors are inoperative, the problem may be caused by one shorted motor. Disconnecting a shorted power lock motor from the power lock circuit will allow the good power lock motor to operate. Disconnect the wire harness connector from each power lock motor, one at a time, and recheck both the lock and unlock functions by operating the power lock switch. If all of the power lock motors are still inoperative after the above test, check for a short or open circuit between the power lock motors and the CTM. If disconnecting one power lock motor causes the other motors to become functional, go to Step 3 to test the disconnected motor. 3. Once it has been determined which power lock motor is inoperative, that motor can be tested as follows. Disconnect the wire harness connector from the inoperative power lock motor. Apply 12 volts to the lock and unlock driver circuit cavities of the power lock motor pigtail wire connector to check its operation in one direction. Reverse the polarity to check the motor operation in the opposite direction. If OK, repair the shorted or open lock or unlock driver circuits between the power lock motor and the CTM as required. If not OK, replace the faulty power lock motor. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Page 6888 Power Door Lock Actuator: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the inner liftgate panel. Fig. 6 Liftgate Power Lock Motor Remove/Install 3. Remove the two screws that secure the power lock motor to the liftgate inner panel. 4. Pull the power lock motor out through the access hole in the liftgate inner panel far enough to access and disconnect the liftgate power lock motor pigtail wire connector from the liftgate wire harness connector. 5. Lower the power lock motor far enough to access and disengage the link from the liftgate latch link clip. 6. Remove the power lock motor from the liftgate. INSTALLATION 1. Position the liftgate power lock motor into the liftgate through the access hole in the liftgate inner panel. 2. Insert the liftgate power lock motor link into the liftgate latch link clip and snap the clip over the link. 3. Reconnect the liftgate power lock motor pigtail wire connector to the liftgate wire harness connector. 4. Position the liftgate power lock motor to the liftgate inner panel. 5. Install and tighten the two screws that secure the power lock motor to the liftgate inner panel. Tighten the screws to 3 Nm (30 in. lbs.). 6. Reinstall the trim panel onto the liftgate inner panel. 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Description and Operation Power Door Lock Control Module: Description and Operation DRIVER DOOR MODULE A Driver Door Module (DDM) is used on all models equipped with power locks, power windows, and power mirrors. The driver door module consists of a molded plastic housing that is secured with three screws to a molded plastic switch bezel. The switch bezel is secured by metal snap clips within an opening near the forward end of the arm rest in the driver side front door trim panel so that the DDM can be serviced without removing the front door trim panel. Two integral connector receptacles on the back of the DDM connect it to the vehicle electrical system through two take outs and connectors of the left front door wire harness. The DDM houses the following switches: Power Lock Switch - The DDM includes a two-way, momentary, resistor multiplexed switch to control the power lock system. - Power Mirror Selector Switch - A three-position rocker switch in the DDM selects the right or left power mirror for adjustment, or turns the power mirror system OFF. - Power Mirror Adjustment Switches - Four momentary, arrowhead shaped, directional switches allow the driver to adjust the selected power mirror in the Up, Down, Right, or Left directions. - Power Window Lockout Switch - A two-way, latching, push-button switch in the DDM allows the vehicle operator to lock out the power window switches on each passenger door so that the passenger door power windows may be operated only from the master switches in the DDM. - Power Window Switches - The DDM houses a two-way, momentary power window switch for the driver side front door. This switch also has a second detent in the Down direction and internal circuitry to provide an Auto-Down feature for the driver side front door power window. In addition to the power window switch for its own door, the DDM houses individual master switches for each passenger door power window. The DDM also incorporates several green Light Emitting Diodes (LEDs) that illuminate the power lock and power window switch paddles, and the power mirror switch directional buttons to improve switch visibility in dark ambient lighting conditions. The DDM cannot be adjusted or repaired and, if faulty or damaged, the entire DDM unit must be replaced. The Driver Door Module (DDM) combines a power lock switch, a driver power window switch with an Auto-down feature, master switches for each passenger door power window, a power window lockout switch, a power mirror selector switch, and four power mirror adjustment switches in a single unit. The switches in the DDM can be diagnosed using conventional diagnostic tools and methods. Power Lock Switch The DDM power lock switch circuitry is connected in series between ground and the driver door switch mux input of the Central Timer Module ( CTM). Each power lock switch position (Lock, Unlock, and Neutral) provides a different resistance value to the CTM input, which allows the CTM to sense the switch position. Based upon the power lock switch input, the CTM controls the battery and ground feed outputs to the individual power lock motors to lock or unlock the door and liftgate latches. The Light-Emitting Diode (LED) in the DDM power lock switch is connected to battery current through the power window circuit breaker in the Junction Block (JB) on a fused ignition switch output (run-acc) circuit so that the switch will be illuminated whenever the ignition switch is in the ON or Accessory positions. Power Window Switches The DDM power window switch circuitry is connected to battery current through a circuit breaker in the Junction Block (JB) on a fused ignition switch output (run-acc) circuit so that the power windows will operate whenever the ignition switch is in the ON or Accessory positions. Each two-way, momentary master passenger power window switch in the DDM provides battery current and ground to the individual power window switches on each passenger door so that the power window switch controls the battery current and ground feeds to its respective power window motor. The DDM switch for the driver side front door power window is labeled with the text "Auto" and includes an auto-down feature. When this switch is depressed to a second momentary detent position and released, the driver door power window is automatically operated through an internal circuit and relay to its fully lowered position. The Auto-down event is cancelled if the switch paddle is depressed a second time in either the Up or Down direction. When the two position window lockout switch in the DDM is depressed and latched in the lockout position, the battery current feed to each of the individual passenger power window switches is interrupted so that the passenger door power windows can only be operated from the master switches in the DDM. The window lockout switch also controls the battery current feed for the LED in each passenger power window switch so that the switch will not be illuminated when it is locked out. Power Mirror Switches The DDM power mirror switch circuitry is connected to battery current through a fuse in the JB on a fused B(+) circuit so that the power mirrors remain operational regardless of the ignition switch position. A rocker type selector switch has three positions, one to select the right mirror, one to select the left mirror, and a neutral OFF position. After the right or left mirror is selected, one of four directional buttons is depressed to move the selected mirror Up, Down, Right or Left. The DDM power mirror switch circuitry controls the battery current and ground feeds to each of the four (two in each mirror head) power mirror motors. The Light-Emitting Diode (LED) in the DDM power mirror switch is connected to battery current through the power window circuit breaker in the Junction Block (JB) on a fused ignition switch output (run-acc) circuit so that the switch directional buttons will be illuminated whenever the ignition switch is in the ON or Accessory positions. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Description and Operation > Page 6892 Power Door Lock Control Module: Testing and Inspection The Light-Emitting Diode (LED) illumination lamps for all of the Driver Door Module (DDM) power window, power lock, and power mirror switches receive battery current through the power window circuit breaker in the Junction Block (JB). If all of the LEDs are inoperative in the DDM, be certain to diagnose the power window system before replacing the switch unit. (Refer to POWER WINDOWS - DIAGNOSIS AND TESTING). If only one LED in the DDM is inoperative, replace the faulty DDM. If the driver side front door power window operates in a normal manner, but the Auto-Down feature is inoperative, replace the faulty DDM. 1. Disconnect and isolate the battery negative cable. Remove the DDM from the door trim panel. Disconnect the door wire harness connectors for the DDM from the DDM connector receptacles. Driver Door Module Switch Tests (Part 1 Of 2) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Description and Operation > Page 6893 Driver Door Module Switch Tests (Part 2 Of 2) Fig.2 Driver Door Module Connector C1 Receptacle Fig. 3 Driver Door Module Connector C2 Receptacle 2. Test the DDM switch continuity. See the Driver Door Module Switch Tests chart to determine if the continuity is correct for the suspect switches in each switch position and/or. If not OK, replace the faulty DDM as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Description and Operation > Page 6894 Power Door Lock Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Fig. 4 Driver Door Module 2. Using a trim stick or another suitable wide flat bladed tool and starting at the rear of the Driver Door Module (DDM) bezel, gently pry the DDM up and out from the driver side front door trim panel. 3. Pull the DDM away from the trim panel opening far enough to access the two connector receptacles on the back of the unit. 4. Disconnect the two door wire harness connectors for the DDM from the DDM connector receptacles. 5. Remove the DDM from the door trim panel. INSTALLATION 1. Position the Driver Door Module (DDM) to the opening in the driver side front door trim panel. 2. Reconnect the two door wire harness connectors for the DDM to the DDM connector receptacles. 3. Insert the front of the DDM bezel into the opening in the driver side front door trim panel. 4. Using hand pressure, gently and evenly press down on the rear of the DDM bezel until it snaps into place. 5. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams Passenger Door Power Lock Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 6898 Power Door Lock Switch: Description and Operation The power lock system can be controlled by a two way, momentary, resistor multiplexed, single gang switch on a power lock and window switch bezel located near the forward end of the armrest on the passenger side front door trim panel. The power lock switch on the driver side front door trim panel is integral to the driver door module. (Refer to POWER LOCKS/DRIVER DOOR MODULE DESCRIPTION). The power lock switch is secured by integral latch tabs in a molded plastic receptacle on the back side of the power window and lock switch bezel so that only the switch paddle is visible where it protrudes through the bezel. The power window and lock switch bezel is secured by small metal snap clips within an opening near the forward end of the arm rest in the passenger side front door trim panel so that the switches can be serviced without removing the front door trim panel. An integral connector receptacle on the back of the switch connects it to the vehicle electrical system through a take out and connector of the right front door wire harness. The power lock switch has a green Light-Emitting Diode (LED) located in the switch paddle to improve switch visibility in dark ambient lighting conditions. The power lock switch cannot be adjusted or repaired and, if faulty or damaged, the switch unit must be replaced. The two-way, momentary, power lock switch on the passenger side front door is connected in series between ground and the passenger door switch mux input of the Central Timer Module (CTM). The power lock switch on the driver side front door trim panel is integral to the driver door module. (Refer to POWER LOCKS/DRIVER DOOR MODULE - OPERATION). Each power lock switch position Lock, Unlock, and Neutral provides a different resistance value to the CTM input which allows the CTM to sense the switch position. Based upon the power lock switch inputs, the CTM controls the battery and ground feed outputs to the power lock motors to lock or unlock the door and liftgate latches. The Light-Emitting Diode (LED) in the paddle of the passenger door power lock switch is connected to battery current through a fuse in the Junction Block (JB) on a fused ignition switch output (run) circuit; therefore, the switch will only be illuminated when the ignition switch is in the On position. The power lock switch can be diagnosed using conventional diagnostic tools and methods. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 6899 Power Door Lock Switch: Testing and Inspection The Light-Emitting Diode (LED) illumination lamp of the power lock switch receives battery current through a fuse in the Junction Block (JB) on a fused ignition switch output (run) circuit. The power lock switch on the driver side front door trim panel is integral to the driver door module. (Refer to POWER LOCKS/DRIVER DOOR MODULE - DIAGNOSIS AND TESTING). If the power lock switch operates, but the LED is inoperative, check for battery current at the switch with the ignition switch in the ON position. If OK, replace the faulty switch. 1. Disconnect and isolate the battery negative cable. Remove the power lock switch from the door trim panel. Disconnect the door wire harness connector for the power lock switch from the switch connector receptacle. Power Lock Switch Test Fig.5 Powr Lock Switch Connector Receptable 2. Test the power lock switch resistance. See the Power Lock Switch Test chart to determine if the resistance is correct for the switch in each switch position. If not OK, replace the faulty power lock switch as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 6900 Power Door Lock Switch: Service and Repair REMOVAL The power lock switch on the driver side front door trim panel is integral to the driver door module. (Refer to POWER LOCKS/DRIVER DOOR MODULE - REMOVAL). 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick or another suitable wide flat bladed tool and starting at the rear of the passenger door power window and lock switch bezel, gently pry the bezel up and out from the passenger side front door trim panel. 3. Pull the power window and lock switch bezel away from the trim panel opening far enough to access the two switch connector receptacles on the back of the unit. 4. Disconnect the door wire harness connectors for the power lock and power window switches from the switch connector receptacles. 5. Remove the power window and lock switch bezel from the door trim panel. 6. Using a small thin-bladed screwdriver, gently pry the snap clips at the sides of the power lock switch receptacle on the back of the power window and lock switch bezel and pull the switch out of the receptacle. INSTALLATION The power lock switch on the driver side front door trim panel is integral to the driver door module. (Refer to POWER LOCKS/DRIVER DOOR MODULE - INSTALLATION). 1. Align the power lock switch with the receptacle on the back of the power window and lock switch bezel. 2. Using hand pressure, gently and evenly press down on the power lock switch it snaps into place in the power window and lock switch bezel receptacle. 3. Position the power window and lock switch bezel to the opening in the passenger side front door trim panel. 4. Reconnect the two door wire harness connectors for the power window and power lock switches to the switch connector receptacles. 5. Insert the front of the power window and lock switch bezel into the opening in the passenger side front door trim panel. 6. Using hand pressure, gently and evenly press down on the rear of the power window and lock switch bezel until it snaps into place. 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair LOCK CYLINDER REMOVAL 1. Remove liftgate trim panels 2. Remove liftgate handle. 3. Remove clip retaining lock cylinder in outside handle. 4. Remove the clip retaining actuator link to lock cylinder. Remove actuator link. Fig. 6 5. Separate lock cylinder from handle (Fig. 6). INSTALLATION 1. Position lock cylinder in outside handle (Fig. 6). 2. Install clip retaining lock cylinder in handle. 3. Install actuator link and retaining clip. 4. Install liftgate handle. 5. Install liftgate trim panels. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Description and Operation Heated Element: Description and Operation HEATED MIRRORS The optional heated mirror system only operates in concert with the rear defogger system, and will be automatically turned OFF after a programmed time interval of about ten minutes. After the initial time interval has expired, if the defogger switch is turned ON again during the same ignition cycle, the heated mirror system will automatically turn OFF after about five minutes. The heated mirror system will automatically shut OFF if the ignition switch is turned to the OFF position, or it can be turned OFF manually by depressing the defogger switch a second time. Refer to the owner's manual in the vehicle glove box for more information on the features, use and operation of the heated mirror system. When the rear window defogger switch is in the ON position, an electric heater grid located behind the glass of each of the outside rear view mirrors is energized. When energized, each of these heater grids produce heat to help clear the outside rear view mirrors of ice, snow, or fog. The heated mirror system is controlled by a momentary rear window defogger switch in the HVAC Control panel, which also includes the switch for the rear wiper and washer system. An amber indicator lamp in the switch control will light to indicate when the defogger system is turned ON. The HVAC control assembly also contains the defogger system control circuitry including the timer logic and the defogger relay. The heated mirror system only operates in concert with the rear defogger system, and will be automatically turned OFF after a programmed time interval of about ten minutes. After the initial time interval has expired, if the defogger switch is turned ON again during the same ignition cycle, the heated mirror system will automatically turn OFF after about five minutes. The heated mirror system will automatically shut OFF if the ignition switch is turned to the OFF position, or it can be turned OFF manually by depressing the defogger switch a second time. Refer to the owner's manual in the vehicle glove box for more information on the features, use and operation of the heated mirror system. Outside Mirror Heating Grid Vehicles equipped with the optional heated mirror system have an electric heating grid located behind the mirror glass of each outside rear view mirror. The heated mirrors are controlled by the rear window defogger switch. Electrical current is directed to the heating grid inside the mirror only when the rear window defogger switch is in the ON position. If the outside mirror heating grids are both inoperative, see Rear Window Defogger System in the Diagnosis and Testing. If only one of the outside mirror heating grids is inoperative (Refer to POWER MIRRORS - DIAGNOSIS AND TESTING). The heating grid behind each outside mirror glass cannot be repaired and, if faulty or damaged, the entire power mirror unit must be replaced (Refer to POWER MIRRORS/SIDEVIEW MIRROR REMOVAL). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Testing and Inspection Power Mirror Switch: Testing and Inspection The power mirror switch is included with the Driver Door Module. (Refer to DOOR MODULE DIAGNOSIS AND TESTING) for service procedures. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Testing and Inspection > Page 6911 Power Mirror Switch: Service and Repair REMOVAL The power mirror switch is included with the Driver Door Module. (Refer to DOOR MODULE REMOVAL) for service procedures. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID Paint: Application and ID Exterior Color Interior Color Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Page 6916 Paint: Description and Operation BASECOAT/CLEARCOAT FINISH DESCRIPTION The original equipment finish is a multi step process that involves cleaning, applying electro deposition (E-coat), anti-chip primer, basecoat, and clearcoat steps. On most vehicles a two-part paint application (basecoat/clearcoat) is used. Color paint that is applied to primer is called basecoat. The clearcoat protects the basecoat from ultraviolet light and provides a durable high-gloss finish. CAUTION: - Do not use abrasive chemicals or compounds on painted surfaces. Damage to finish can result. - Do not use harsh alkaline based cleaning solvents on painted surfaces. Damage to finish or color can result. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Paint Touch-Up Paint: Service and Repair Paint Touch-Up PAINT TOUCH-UP DESCRIPTION When a painted metal surface has been scratched or chipped, it should be touched up as soon as possible to avoid corrosion. For best results, use MOPAR Scratch Filled Primer, Touch-Up Paints and Clear Top Coat. WARNING: USE AN OSHA APPROVED RESPIRATOR AND SAFETY GLASSES WHEN SPRAYING PAINT OR SOLVENTS IN A CONFINED AREA. PERSONAL INJURY CAN RESULT. STANDARD PROCEDURE-PAINT TOUCH-UP 1. Scrape loose paint and corrosion from inside scratch or chip. 2. Clean affected area with MOPAR Tar/Road Oil Remover or equivalent, and allow to dry. 3. Fill the inside of the scratch or chip with a coat of filled primer. Do not overlap primer onto good surface finish. The applicator brush should be wet enough to puddle-fill the scratch or chip without running. Do not stroke brush applicator on body surface. Allow the filled primer to dry hard. 4. Cover the filled primer with color touch-up paint. Do not overlap touch-up color onto the original color coat around the scratch or chip. Butt the new color to the original color, if possible. Do not stroke applicator brush on body surface. Allow touch-up paint to dry hard. 5. On vehicles without clearcoat, the touch-up color can be lightly finesse sanded (1500 grit) and polished with rubbing compound. 6. On vehicles with clearcoat, apply clear top coat to touch-up paint with the same technique as described in Step 4. Allow clear top coat to dry hard. If desired, Step 5 can be performed on clear top coat. WARNING: AVOID PROLONGED SKIN CONTACT WITH PETROLEUM OR ALCOHOL-BASED CLEANING SOLVENTS. PERSONAL INJURY CAN RESULT. AVOID PROLONGED SKIN CONTACT WITH PETROLEUM OR ALCOHOL-BASED CLEANING SOLVENTS. PERSONAL INJURY CAN RESULT. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Paint Touch-Up > Page 6919 Paint: Service and Repair Finesse Sanding, Buffing, And Polishing - Description FINESSE SANDING/BUFFING & POLISHING DESCRIPTION CAUTION: Do not remove more than 0.5 mils of clearcoat finish, if equipped. Basecoat paint must retain clearcoat for durability. Use a Paint Thickness Gauge #PR-ETG-2X or equivalent to determine film thickness before and after the repair. Minor acid etching, orange peel, or smudging in clearcoat or single-stage finishes can be reduced with light finesse sanding, hand buffing, and polishing. If the finish has been finesse sanded in the past, it cannot be repeated. Finesse sanding operation should be performed by a trained automotive paint technician. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams Door Module: Diagrams Driver Door Module C1 Driver Door Module C2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Description and Operation Power Door Lock Control Module: Description and Operation DRIVER DOOR MODULE A Driver Door Module (DDM) is used on all models equipped with power locks, power windows, and power mirrors. The driver door module consists of a molded plastic housing that is secured with three screws to a molded plastic switch bezel. The switch bezel is secured by metal snap clips within an opening near the forward end of the arm rest in the driver side front door trim panel so that the DDM can be serviced without removing the front door trim panel. Two integral connector receptacles on the back of the DDM connect it to the vehicle electrical system through two take outs and connectors of the left front door wire harness. The DDM houses the following switches: Power Lock Switch - The DDM includes a two-way, momentary, resistor multiplexed switch to control the power lock system. - Power Mirror Selector Switch - A three-position rocker switch in the DDM selects the right or left power mirror for adjustment, or turns the power mirror system OFF. - Power Mirror Adjustment Switches - Four momentary, arrowhead shaped, directional switches allow the driver to adjust the selected power mirror in the Up, Down, Right, or Left directions. - Power Window Lockout Switch - A two-way, latching, push-button switch in the DDM allows the vehicle operator to lock out the power window switches on each passenger door so that the passenger door power windows may be operated only from the master switches in the DDM. - Power Window Switches - The DDM houses a two-way, momentary power window switch for the driver side front door. This switch also has a second detent in the Down direction and internal circuitry to provide an Auto-Down feature for the driver side front door power window. In addition to the power window switch for its own door, the DDM houses individual master switches for each passenger door power window. The DDM also incorporates several green Light Emitting Diodes (LEDs) that illuminate the power lock and power window switch paddles, and the power mirror switch directional buttons to improve switch visibility in dark ambient lighting conditions. The DDM cannot be adjusted or repaired and, if faulty or damaged, the entire DDM unit must be replaced. The Driver Door Module (DDM) combines a power lock switch, a driver power window switch with an Auto-down feature, master switches for each passenger door power window, a power window lockout switch, a power mirror selector switch, and four power mirror adjustment switches in a single unit. The switches in the DDM can be diagnosed using conventional diagnostic tools and methods. Power Lock Switch The DDM power lock switch circuitry is connected in series between ground and the driver door switch mux input of the Central Timer Module ( CTM). Each power lock switch position (Lock, Unlock, and Neutral) provides a different resistance value to the CTM input, which allows the CTM to sense the switch position. Based upon the power lock switch input, the CTM controls the battery and ground feed outputs to the individual power lock motors to lock or unlock the door and liftgate latches. The Light-Emitting Diode (LED) in the DDM power lock switch is connected to battery current through the power window circuit breaker in the Junction Block (JB) on a fused ignition switch output (run-acc) circuit so that the switch will be illuminated whenever the ignition switch is in the ON or Accessory positions. Power Window Switches The DDM power window switch circuitry is connected to battery current through a circuit breaker in the Junction Block (JB) on a fused ignition switch output (run-acc) circuit so that the power windows will operate whenever the ignition switch is in the ON or Accessory positions. Each two-way, momentary master passenger power window switch in the DDM provides battery current and ground to the individual power window switches on each passenger door so that the power window switch controls the battery current and ground feeds to its respective power window motor. The DDM switch for the driver side front door power window is labeled with the text "Auto" and includes an auto-down feature. When this switch is depressed to a second momentary detent position and released, the driver door power window is automatically operated through an internal circuit and relay to its fully lowered position. The Auto-down event is cancelled if the switch paddle is depressed a second time in either the Up or Down direction. When the two position window lockout switch in the DDM is depressed and latched in the lockout position, the battery current feed to each of the individual passenger power window switches is interrupted so that the passenger door power windows can only be operated from the master switches in the DDM. The window lockout switch also controls the battery current feed for the LED in each passenger power window switch so that the switch will not be illuminated when it is locked out. Power Mirror Switches The DDM power mirror switch circuitry is connected to battery current through a fuse in the JB on a fused B(+) circuit so that the power mirrors remain operational regardless of the ignition switch position. A rocker type selector switch has three positions, one to select the right mirror, one to select the left mirror, and a neutral OFF position. After the right or left mirror is selected, one of four directional buttons is depressed to move the selected mirror Up, Down, Right or Left. The DDM power mirror switch circuitry controls the battery current and ground feeds to each of the four (two in each mirror head) power mirror motors. The Light-Emitting Diode (LED) in the DDM power mirror switch is connected to battery current through the power window circuit breaker in the Junction Block (JB) on a fused ignition switch output (run-acc) circuit so that the switch directional buttons will be illuminated whenever the ignition switch is in the ON or Accessory positions. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Description and Operation > Page 6927 Power Door Lock Control Module: Testing and Inspection The Light-Emitting Diode (LED) illumination lamps for all of the Driver Door Module (DDM) power window, power lock, and power mirror switches receive battery current through the power window circuit breaker in the Junction Block (JB). If all of the LEDs are inoperative in the DDM, be certain to diagnose the power window system before replacing the switch unit. (Refer to POWER WINDOWS - DIAGNOSIS AND TESTING). If only one LED in the DDM is inoperative, replace the faulty DDM. If the driver side front door power window operates in a normal manner, but the Auto-Down feature is inoperative, replace the faulty DDM. 1. Disconnect and isolate the battery negative cable. Remove the DDM from the door trim panel. Disconnect the door wire harness connectors for the DDM from the DDM connector receptacles. Driver Door Module Switch Tests (Part 1 Of 2) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Description and Operation > Page 6928 Driver Door Module Switch Tests (Part 2 Of 2) Fig.2 Driver Door Module Connector C1 Receptacle Fig. 3 Driver Door Module Connector C2 Receptacle 2. Test the DDM switch continuity. See the Driver Door Module Switch Tests chart to determine if the continuity is correct for the suspect switches in each switch position and/or. If not OK, replace the faulty DDM as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Description and Operation > Page 6929 Power Door Lock Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Fig. 4 Driver Door Module 2. Using a trim stick or another suitable wide flat bladed tool and starting at the rear of the Driver Door Module (DDM) bezel, gently pry the DDM up and out from the driver side front door trim panel. 3. Pull the DDM away from the trim panel opening far enough to access the two connector receptacles on the back of the unit. 4. Disconnect the two door wire harness connectors for the DDM from the DDM connector receptacles. 5. Remove the DDM from the door trim panel. INSTALLATION 1. Position the Driver Door Module (DDM) to the opening in the driver side front door trim panel. 2. Reconnect the two door wire harness connectors for the DDM to the DDM connector receptacles. 3. Insert the front of the DDM bezel into the opening in the driver side front door trim panel. 4. Using hand pressure, gently and evenly press down on the rear of the DDM bezel until it snaps into place. 5. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations Seat Heater Control Module: Locations Fig. 8 Heated Seat Module - Typical The heated seat module is located under the heated seat switches, where it is secured to a mounting bracket that is also part of the center console. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 6933 Heated Seat Module Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 6934 Seat Heater Control Module: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 6935 Seat Heater Control Module: Description and Operation Fig. 8 Heated Seat Module - Typical HEATED SEAT MODULE Vehicles equipped with heated seats utilize a heated seat module. The heated seat module is located under the heated seat switches, where it is secured to a mounting bracket that is also part of the center console. The heated seat module has a single connector receptacle that allows the module to be connected to all of the required inputs and outputs through the center console wire harness. The heated seat module is an electronic microprocessor controlled device designed and programmed to use inputs from the ignition switch, the two heated seat switches and the two heated seat sensors to operate and control the heated seat elements in both front seats and the two heated seat indicator lamp Light-Emitting Diodes (LEDs) in each heated seat switch. The heated seat module is also programmed to perform self-diagnosis of certain heated seat system functions and provide feedback of that diagnosis through the heated seat switch indicator lamps. The heated seat module cannot be repaired. If the heated seat module is damaged or faulty, the entire module must be replaced. The heated seat module operates on fused battery current received from the ignition switch. The module is grounded at all times through a ground screw located on the drivers B-pillar. Inputs to the module include a resistor multiplexed heated seat switch request circuit for each of the two heated seat switches and the heated seat sensor inputs from the seat cushions of each front seat. In response to those inputs the heated seat module controls battery current feeds to the heated seat elements and sensors, and controls the ground for the heated seat switch indicator lamps. When a heated seat switch (Driver or Passenger) request signal is received by the heated seat module, the module energizes the proper indicator lamp (Low or High) in the switch by grounding the indicator lamp circuit to indicate that the heated seat system is operating. At the same time, the heated seat module energizes the selected heated seat sensor circuit and the sensor provides the module with an input indicating the surface temperature of the selected seat cushion. The Low heat set point is about 35 °C (100.4 °F), and the High heat set point is about 42 °C (107.6 °F). If the seat cushion surface temperature input is below the temperature set point for the selected temperature setting, the heated seat module energizes an N-channel Field Effect Transistor (N-FET) within the module which energizes the heated seat elements in the selected seat cushion and back. When the sensor input to the module indicates the correct temperature set point has been achieved, the module de-energizes the N-FET which de-energizes the heated seat elements. The heated seat module will continue to cycle the N-FET as needed to maintain the selected temperature set point. If the heated seat module detects a heated seat sensor value input that is out of range or a shorted or open heated seat element circuit, it will notify the vehicle operator or the repair technician of this condition by flashing the High and/or Low indicator lamps in the affected heated seat switch. Refer to Heated Seat System and Heated Seat Module in Electronic Control Modules for the location of the proper heated seat module diagnosis and testing procedures. Also refer to the Body Diagnostic for additional diagnosis and testing procedures. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 6936 Seat Heater Control Module: Testing and Inspection Refer to Wiring Diagrams in for the location of complete heated seat system wiring diagrams. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. If a heated seat fails to heat and one or both of the indicator lamps on a heated seat switch flash, refer to Heated Seat System in the Electrical for the location of the proper heated seat system diagnosis and testing procedures. If a heated seat heats but one or both indicator lamps on the heated seat switch fail to operate, test the heated seat switch. Refer to Heated Seat Switch in the heated seat for the location of the proper heated seat switch diagnosis and testing procedures. If the heated seat switch checks OK, go to Step 4. If both seats (driver and passenger) fail to heat and the indicator lamps on the heated seat switches for both seats fail to operate, test the ignition switch output circuit. If OK, go to Step 2 If not OK, repair the battery feed circuits to the heated seat switches. If only one seat (driver or passenger) fails to heat and the indicator lamps on the heated seat switch for that seat fail to operate, test that heated seat switch. Refer to Heated Seat Switch in the heated seat for the location of the proper heated seat switch diagnosis and testing procedures. If the heated seat switch checks OK, go to Step 3. If a heated seat switch indicator lamp remains illuminated after the heated seat has been turned OFF, go to Step 5. 2. Disconnect and isolate the battery negative cable. Disconnect the wire harness connector for the heated seat module from the heated seat module connector receptacle. Check for continuity between the ground circuit cavity of the wire harness connector for the heated seat module and a good ground. If not OK, repair the open ground circuit to ground as required. If OK, reconnect the battery negative cable. Turn the ignition switch to RUN position and check for battery voltage at the heated seat module connector receptacle. If OK, go to (3). If not OK, repair battery feed circuit to the heated seat module connector receptacle. 3. Turn the ignition switch to the OFF position. Disconnect the wire harness connector for the heated seat module from the heated seat module connector receptacle. Remove the heated seat switches from the center console. Disconnect the wire harness connector(s) from the connector receptacle(s) of the inoperative heated seat switch(es). Check for continuity between the inoperative driver and/or passenger heated seat switch circuit cavities of the heated seat switch wire harness connector(s) and the heated seat module wire harness connector. There should be continuity. If OK, replace the faulty heated seat module. If not OK, repair the open driver and/or passenger heated seat switch circuit as required. 4. Disconnect and isolate the battery negative cable. Disconnect the wire harness connector for the heated seat module from the heated seat module connector receptacle. Remove the heated seat switches from the center console. Check for continuity between the inoperative left and/or right seat high and/or low heat LED driver circuit cavities of the heated seat switch wire harness connector(s) and the heated seat module wire harness connector. There should be continuity. If OK, replace the faulty heated seat module. If not OK, repair the open left or right seat high or low heat LED driver circuit as required. 5. Disconnect and isolate the battery negative cable. Disconnect the wire harness connector for the heated seat module from the heated seat module connector receptacle. Remove the heated seat switches from the center console. Disconnect the center console wire harness connector(s) from the connector receptacle(s) of the heated seat switch(es) with the inaccurate indicator lamp(s). Check for continuity between the inoperative left and/or right seat high and/or low heat LED driver circuit cavity of the heated seat switch wire harness connector(s) and a good ground. There should be no continuity. If OK, replace the faulty heated seat module. If not OK, repair the shorted left or right seat high or low heat LED driver circuit as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 6937 Seat Heater Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the seat heater switches from the center console. Refer to the procedure in the Heated Seat. 3. Open the center console and remove the center console insert and floor mat, if equipped. 4. Using a long flat bladed screwdriver, insert the screwdriver through the heated switch mounting holes in the center console and depress the heated seat module mounting bracket retaining tabs. With the retaining tabs depressed reach into the center console and tilt the front wall of the console rearward. The heated seat module is now visible. 5. Remove the heated seat module from the mounting bracket by removing the retaining screws. 6. Disconnect the center console wire harness connector from the connector receptacle on the back of the heated seat module. 7. Remove the heated seat module from the vehicle. INSTALLATION 1. Position the heated seat module in the center console. 2. Connect the center console wire harness connector on the connector receptacle on the back of the heated seat module. 3. Install the heated seat module retaining screws. 4. Rotate the front center console wall up into position and install the center console insert and floor mat, if equipped. 5. Install the seat heater switches in the center console. Refer to the procedure in the heated seat. 6. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Luggage Rack > Component Information > Service and Repair Luggage Rack: Service and Repair LUGGAGE RACK REMOVAL Fig. 10 1. Remove screws attaching side rail to roof panel (Fig. 10). 2. Separate luggage rack from vehicle. NOTE: The skid strips are attached to roof panel with adhesive. 3. Loosen each skid strip with a heat gun. 4. Lift one edge of each skid strip with a putty knife and peel it from roof panel. Apply additional heat to any location where a skid strip remains. 5. Remove original adhesive from roof panel with an all-purpose adhesive removal solution. INSTALLATION NOTE: Thoroughly clean and prepare the roof surface. 1. Align each skid strip on roof panel. 2. Verify that each skid strip is properly aligned. 3. Remove the carrier backing and press each skid strip onto roof panel with a roller. NOTE: Apply 3M Drip-Chek Sealant (or an equivalent product) to side rail screw threads. 4. Position luggage rack on roof. 5. Install screws attaching side rail to roof panel (Fig. 10). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Technical Service Bulletins > FMVSS201 - Head Impact Safety Standards Sunroof / Moonroof: Technical Service Bulletins FMVSS201 - Head Impact Safety Standards NUMBER: 23-003-01 GROUP: Body DATE: Feb. 2, 2001 SUBJECT: Federal Motor Vehicle Safety Standard (FMVSS) 201 - Head Impact Upper Interior MODELS: 2001 (AB) Ram Van/Wagon 2001 (AN) Dakota 2001 (BR/BE)Ram Pickup 2001 (DN) Durango 2001 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 2001 (LH) Concorde/Intrepid/LHS/300M 2001 (PL) Neon 2001 (PR) Prowler 2001 (PT) PT Cruiser 2001 (RS) Town & Country/Caravan/Voyager 2001 (SR) Viper 2001 (ST) Sebring Coupe/Stratus Coupe 2001 (TJ) Wrangler 2001 (WJ) Grand Cherokee 2001 (XJ) Cherokee DISCUSSION: All factory installed equipment, such as a sunroof, meet the upper interior head protection requirements of FMVSS 201. Sunroofs or other equipment installed in new vehicles by dealerships or for dealerships must also meet the requirements of FMVSS 201. WARNING: DEALERS INSTALLING OR HAVING INSTALLED EQUIPMENT NOT MEETING FMVSS 201 STANDARDS ON NEW VEHICLES MAY BE ASSUMING LIABILITY FOR HEAD IMPACT INJURIES IN THAT AREA. FMVSS questions should be directed to the National Highway Traffic Safety Administration (NHTSA) at 1-800-424-9393. POLICY: Information Only Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair Head Rest: Service and Repair HEADREST SLEEVE REMOVAL NOTE: When removing the head restraint sleeves and guides, the retaining tabs on the sleeves will be damaged during the removal process. Check the availability of replacement parts before servicing. 1. Remove head restraint. Fig. 1 2. Using a trim stick C-4755 or equivalent, pry head restraint sleeves and guides from seat back. (Fig. 1). 3. Separate head restraint sleeves and guides from seat back and discard. INSTALLATION 1. Position new head restraint sleeves and guides in seat back. 2. Rotate head restraint sleeve until aligned with slot in the guide and press downward to secure. Ensure head restraint sleeve is anchored securely. 3. Install head restraint. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams Power Seat Motor: Diagrams Driver Power Lumbar Motor Driver Power Seat Motors Passenger Power Lumbar Motor Passenger Power Seat Motors Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Page 6953 Power Seat Motor: Description and Operation LUMBAR MOTOR The 8-way power seat option includes an electrically operated lumbar support mechanism. The only visible evidence of this option is the separate power lumbar switch control paddle that is located on the outboard seat cushion side shield, next to the other power seat switch control knobs. The power lumbar adjuster and motor are concealed beneath the seat back trim cover and padding, where they are secured to the seat back frame. The power lumbar adjuster cannot be repaired, and is serviced only as a unit with the seat back frame. If the power lumbar adjuster or the seat back frame are damaged or faulty, the entire seat back frame unit must be replaced. Refer to Bucket Seat Back in Body for the seat back frame service procedures. The power lumbar adjuster mechanism includes a reversible electric motor that is secured to the seat back frame and is connected to a worm-drive gearbox. The motor and gearbox operate the lumbar adjuster mechanism in the center of the seat back by extending and retracting a cable that actuates a lever. The action of this lever compresses or relaxes a basket. The more this basket is compressed, the more the slats bow outward against the center of the seat back padding, providing additional lumbar support. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Page 6954 Power Seat Motor: Testing and Inspection Power Seat Lumbar Adjuster and Motor Test Actuate the power lumbar switch to move the power lumbar adjuster in each direction. The power lumbar adjuster should move in both directions. It should be noted that the power lumber adjuster normally operates very quietly and exhibits little visible movement. If the power lumbar adjuster fails to operate in only one direction, move the adjuster a short distance in the opposite direction and test again to be certain that the adjuster is not at its travel limit. If the power lumbar adjuster still fails to operate in only one direction, refer to Power Lumbar Switch in the Diagnosis and Testing. If the power lumbar adjuster fails to operate in either direction, perform the following tests. 1. Check the power seat fuse in the power distribution center. If OK, go to Step 2. If not OK, replace the faulty power seat fuse. 2. Check for battery voltage at the power seat fuse in the power distribution center. If OK, go to Step 3. If not OK, repair the open fused B(+) circuit to the fuse in the Power Distribution Center as required. 3. Remove the outboard seat cushion side shield from the seat. Disconnect the seat wire harness connector from the power lumbar switch connector receptacle. Check for battery voltage at the fused B(+) circuit cavity of the power seat wire harness connector for the power lumbar switch. If OK, go to Step 4, If not OK, repair the open fused B(+) circuit to the power seat fuse in the power distribution center as required. 4. Check for continuity between the ground circuit cavity of the power seat wire harness connector for the power lumbar switch and a good ground. There should be continuity. If OK, go to Step 5. If not OK, repair the open ground circuit to ground as required. 5. Test the power lumbar switch. Refer to Power Lumbar Switch in the Diagnosis and Testing. If the switch tests OK, test the circuits of the power seat wire harness between the power lumbar adjuster motor and the power lumbar switch for shorts or opens. If the circuits check OK, replace the faulty seat back frame assembly. If the circuits are not OK, repair the power seat wire harness as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations Power Seat Switch: Locations The switch is located on the lower outboard side of the seat cushion on the seat cushion side shield on all models. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Page 6958 Power Seat Switch: Diagrams Driver Power Seat Switch Passenger Power Seat Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Page 6959 Power Seat Switch: Description and Operation DRIVER POWER SEAT SWITCH The power seat can be adjusted in six different ways using the power seat switch. The power seat switch for some models has an additional switch knob for adjusting the power lumbar support. The switch is located on the lower outboard side of the seat cushion on the seat cushion side shield on all models. Refer to the owner's manual in the vehicle glove box for more information on the power seat switch functions and the seat adjusting procedures. The individual switches in the power seat switch module cannot be repaired. If one switch is damaged or faulty, the entire power seat switch module must be replaced. When a power switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track or recliner adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. PASSENGER POWER SEAT SWITCH The power seat can be adjusted in six different ways using the power seat switch. The power seat switch for some models has an additional switch knob for adjusting the power lumbar support. The switch is located on the lower outboard side of the seat cushion on the seat cushion side shield on all models. Refer to the owner's manual in the vehicle glove box for more information on the power seat switch functions and the seat adjusting procedures. The individual switches in the power seat switch module cannot be repaired. If one switch is damaged or faulty, the entire power seat switch module must be replaced. When a power switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track or recliner adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Driver Power Seat Switch Test Power Seat Switch: Testing and Inspection Driver Power Seat Switch Test 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat. Driver Power Seat Switch Test Fig. 1 Driver Seat Switch 3. Use an ohmmeter to test the continuity of the power seat switches in each position. See the Power Seat Switch Continuity chart and figure. If OK, see Power Seat Adjuster and Motors or Power Lumbar Adjuster and Motor in the Diagnosis and Testing. If not OK, replace the faulty power seat switch unit. CAUTION: Be certain the two halves of the power seat switch assembly are completely snapped together. Failure to do so could result in a misdiagnosed power seat switch. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Driver Power Seat Switch Test > Page 6962 Power Seat Switch: Testing and Inspection Passenger Power Seat Switch Test 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat. Passenger Power Seat Switch Test Fig. 2 Passenger Power Seat Switch 3. Use an ohmmeter to test the continuity of the power seat switches in each position. See the Power Seat Switch Continuity chart and figure. If OK, see Power Seat Adjuster and Motors or Power Lumbar Adjuster and Motor in the Diagnosis and Testing. If not OK, replace the faulty power seat switch unit. CAUTION: Be certain the two halves of the power seat switch assembly are completely snapped together. Failure to do so could result in a misdiagnosed power seat switch. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Driver Power Seat Switch Replacement Power Seat Switch: Service and Repair Driver Power Seat Switch Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the seat cushion side shield from the seat. Refer to Body for the procedure. 3. Pull the switch bezel or side shield unit out from the seat far enough to access the switch wire harness connector. Gently pry the locking tabs of the switch away from the wire harness connector and carefully unplug the connector from the power seat switch module. 4. Remove the screws that secure the power seat switch. INSTALLATION 1. Position the power seat switch on the seat cushion side shield and connect the electrical connector. 2. Install the screws that secure the power seat switch to seat cushion side shield. 3. Install the seat cushion side shield on the seat. Refer to Body for the procedure. 4. If equipped, install the recliner lever on the recliner mechanism release shaft. 5. If equipped, install the screw that secures the recliner lever to the recliner mechanism release shaft on the outboard side of the front seat. 6. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Driver Power Seat Switch Replacement > Page 6965 Power Seat Switch: Service and Repair Passenger Power Seat Switch Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the seat cushion side shield from the seat. Refer to Body for the procedure. 3. Pull the switch bezel or side shield unit out from the seat far enough to access the switch wire harness connector. Gently pry the locking tabs of the switch away from the wire harness connector and carefully unplug the connector from the power seat switch module. 4. Remove the screws that secure the power seat switch. INSTALLATION 1. Position the power seat switch on the seat cushion side shield and connect the electrical connector. 2. Install the screws that secure the power seat switch to seat cushion side shield. 3. Install the seat cushion side shield on the seat. Refer to Body for the procedure. 4. If equipped, install the recliner lever on the recliner mechanism release shaft. 5. If equipped, install the screw that secures the recliner lever to the recliner mechanism release shaft on the outboard side of the front seat. 6. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions Seat Heater: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 6970 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 6971 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 6972 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 6973 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 6974 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 6975 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 6976 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 6977 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 6978 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 6979 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 6980 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 6981 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 6982 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 6983 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 6984 Seat Heater: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 6985 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 6986 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 6987 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 6988 Seat Heater: Connector Views Driver Heated Seat Passenger Heated Seat Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 6989 Seat Heater: Electrical Diagrams Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 6990 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 6991 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Page 6992 Seat Heater: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Page 6993 Seat Heater: Description and Operation HEATED SEAT SYSTEM Individually controlled electrically heated front seats are available factory-installed optional equipment on the Durango models that are also equipped with the optional leather trim package. Vehicles with this option can be visually identified by the two separate heated seat switches mounted in the center console. The heated seat system allows the front seat driver and passenger to select from two different levels of supplemental electrical seat heating, or no seat heating to suit their individual comfort requirements. The heated seat system for this vehicle includes the following major components: The heated seat switches, including two heated seat Light-Emitting Diode (LED) indicator lamps and three back lighting LED's for each switch. - The heated seat module, also referred to as the Seat Heat Interface Module (SHIM), which contains the solid state electronic control and diagnostic logic circuitry for the heated seat system. - The heated seat elements and sensors, which are integral to the individual front seat cushion and front seat back trim covers. Following are general descriptions of the major components in the heated seat system. See the owner's manual in the vehicle glove box for more information on the features, use and operation of the heated seat system. Refer to Power Seat for the location of complete heated seat system wiring diagrams. The heated seat module receives fused battery current through Junction Block (JB) only when the ignition switch is in the run position. The heated seat switches receive battery current through a fused ignition switch output (run) circuit only when the ignition switch is in the Run position. The heated seat module shares a common ground circuit with each of the heated seat elements. The heated seat elements will only operate when the surface temperature of the seat cushion cover at the heated seat sensors is below the designed temperature set points of the system. The heated seat module will automatically turn OFF the heated seat elements if it detects a short in the heated seat element circuit or a heated seat sensor value that is out of range. The heated seat system will also be turned OFF automatically whenever the ignition switch is turned to any position except Run. If the ignition switch is turned to the OFF position the heated seat will remain OFF after the ignition switch is turned to the ON position until a heated seat switch is depressed again. The heated seat module monitors inputs from the heated seat sensors and the heated seat switches. In response to these inputs the heated seat module uses its internal programming to control outputs to the heated seat elements in both front seats and to control the heated seat LED indicator lamps located in both of the heated seat switches. The heated seat module is also programmed to provide a self-diagnostic capability. When the module detects certain failures within the heated seat system, it will provide a visual indication of the failure by flashing the indicator lamps in the heated seat switches. DRIVER SEAT HEATER SWITCH The heated seat switches used on vehicles with this option are both mounted in the center console. The two switches are snapped into mounting holes in the center console. The two heated seat switches are identical in appearance and construction, except for the location of a keyway in the single connector receptacle and the housing on the back of each switch. The instrument panel wire harness connectors for the heated seat switches are keyed to match the connector receptacles on the switches so that the two heated seat switches can only be connected to the proper heated seat. The momentary, bidirectional rocker-type heated seat switch provides a resistor-multiplexed signal to the heated seat module. Each switch has a center neutral position and momentary Low and High positions so that both the driver and the front seat passenger can select a preferred seat heating mode. Each heated seat switch has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected mode (Low or High) of the seat heater for each seat and to provide diagnostic feedback for the heated seat system. Each switch also has three other LED indicator lamps, which provides back lighting of the switch nomenclature when the ignition switch is in the Run position. The five LED indicator lamps in each heated seat switch cannot be repaired. If the indicator or back lighting lamps are faulty or damaged, the individual heated seat switch unit must be replaced. The heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the ON position. Depressing the heated seat switch rocker to its momentary High or Low position provides a hard-wired resistor multiplexed voltage request signal to the heated seat module to power the heated seat element of the selected seat and maintain the requested temperature setting. If the heated seat switch is depressed to a different position (Low or High) than the currently selected state, the heated seat module will change states to support the new selection. If a heated seat switch is depressed a second time to the same position as the currently selected state, the heated seat module interprets the second input as a request to turn the seat heater OFF. The heated seat module will then turn the heated seat elements for that seat OFF. The indicator lamps in the heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the ON position. The ground side of each indicator lamp is controlled by a separate (high or low/driver or passenger) indicator lamp driver circuit by the heated seat module. The heated seat module control of the switch indicator lamps also allows the module to provide diagnostic feedback to the vehicle operator to indicate monitored heated seat system faults by flashing the indicator lamps ON and OFF. One side of the back lighting LED's in each heated seat switch are connected in series to ground at all times. The other side of the LED's are connected to the ignition switch run circuit. These LED's are energized when the ignition switch is turned to the Run position. HEATED SEAT ELEMENT & SENSOR One end of the heated seat element resistor wire is connected to a ground feed at all times through a splice in the heated seat module ground Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Page 6994 circuit. Battery current is directed to the other end of the heated seat element resistor wire by the energized N-channel Field Effect Transistor (N-FET) located within the heated seat module. The heated seat module will energize the N-FET only when the heated seat switch is in the Low or High position and the heated seat sensor indicates that the seat cushion surface temperature is below the selected (Low or High) temperature set point. As electrical current passes through the heating element grid, the resistance of the wire used in the element disperses some of that electrical current in the form of heat. The heat produced by the heated seat element grid then radiates through the underside of the seat cushion and seat back trim covers, warming the seat cover and its occupant. The resistance of the heated seat sensor increases and decreases as the surface temperature of the seat cushion cover changes. The heated seat module supplies each sensor with a voltage feed, then detects the sensor resistance by monitoring the voltage of the separate sensor return circuits. The heated seat module compares the heated seat sensor resistance (seat cushion surface temperature) with the heated seat switch resistance (Low or High set point) to determine when the heated seat element grids need to be cycled ON or OFF in order to maintain the selected temperature set point. PASSENGER SEAT HEATER SWITCH The heated seat switches used on vehicles with this option are both mounted in the center console. The two switches are snapped into mounting holes in the center console. The two heated seat switches are identical in appearance and construction, except for the location of a keyway in the single connector receptacle and the housing on the back of each switch. The instrument panel wire harness connectors for the heated seat switches are keyed to match the connector receptacles on the switches so that the two heated seat switches can only be connected to the proper heated seat. The momentary, bidirectional rocker-type heated seat switch provides a resistor-multiplexed signal to the heated seat module. Each switch has a center neutral position and momentary Low and High positions so that both the driver and the front seat passenger can select a preferred seat heating mode. Each heated seat switch has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected mode (Low or High) of the seat heater for each seat and to provide diagnostic feedback for the heated seat system. Each switch also has three other LED indicator lamps, which provides back lighting of the switch nomenclature when the ignition switch is in the Run position. The five LED indicator lamps in each heated seat switch cannot be repaired. If the indicator or back lighting lamps are faulty or damaged, the individual heated seat switch unit must be replaced. The heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the ON position. Depressing the heated seat switch rocker to its momentary High or Low position provides a hard-wired resistor multiplexed voltage request signal to the heated seat module to power the heated seat element of the selected seat and maintain the requested temperature setting. If the heated seat switch is depressed to a different position (Low or High) than the currently selected state, the heated seat module will change states to support the new selection. If a heated seat switch is depressed a second time to the same position as the currently selected state, the heated seat module interprets the second input as a request to turn the seat heater OFF. The heated seat module will then turn the heated seat elements for that seat OFF. The indicator lamps in the heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the ON position. The ground side of each indicator lamp is controlled by a separate (high or low/driver or passenger) indicator lamp driver circuit by the heated seat module. The heated seat module control of the switch indicator lamps also allows the module to provide diagnostic feedback to the vehicle operator to indicate monitored heated seat system faults by flashing the indicator lamps ON and OFF. One side of the back lighting LED's in each heated seat switch are connected in series to ground at all times. The other side of the LED's are connected to the ignition switch run circuit. These LED's are energized when the ignition switch is turned to the Run position. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Heated Seat Element and Sensor Test Seat Heater: Testing and Inspection Heated Seat Element and Sensor Test The heated seat module will self-diagnose shorted or open heated seat element circuits and the sensor circuits. Refer to Heated Seat System for the location of the proper heated seat system diagnosis and testing procedures. To manually check the heated seat element and sensor circuits, proceed as follows. The wire harness connectors for the seat cushion heated seat element and sensor and for the seat back heated seat element are located under the seat, near the rear edge of the seat cushion frame. Heated Seat Element 1. Disconnect and isolate the battery negative cable. Disconnect the 4-way heated seat wire harness connector. Check for continuity between the two heated seat element circuit cavities in the seat cushion trim cover half of the 4-way heated seat wire harness connector. There should be continuity. If OK, go to Step 2. If not OK, go to Step 3. 2. Check for continuity between one of the heated seat element circuit cavities in the seat cushion trim cover half of the 4-way heated seat wire harness connector and the seat cushion frame. There should be no continuity. If OK, go to Step 5. If not OK, go to Step 4. 3. Disconnect the 2-way heated seat wire harness connector between the seat cushion trim cover and the seat back trim cover. Check for continuity between the heated seat element circuit cavity and the ground circuit cavity in the seat back trim cover half of the 2-way heated seat wire harness connector. There should be continuity. If OK, go to Step 5. If not OK, replace the faulty seat back trim cover unit. 4. Check for continuity between the heated seat element circuit cavity in the seat back trim cover half of the 2-way heated seat wire harness connector and the seat back frame. There should be no continuity. If OK, go to Step 5. If not OK, replace the faulty seat back trim cover unit. 5. Test the seat wire harness between the heated seat module connector and the 4-way heated seat wire harness connectors for shorted or open circuits. If OK, replace the faulty seat cushion trim cover unit. If not OK, repair the shorted or open seat wire harness as required. Heated Seat Sensor 1. Disconnect and isolate the battery negative cable. Disconnect the 4-way heated seat wire harness connector. Using an ohmmeter, check the resistance between the heated seat sensor input circuit cavity and the heated seat sensor feed circuit cavity in the seat cushion cover half of the 4-way heated seat wire harness connector. The heated seat sensor resistance should be between 600 ohms and 200 kilo ohms. If OK, go to Step 2. If not OK, replace the faulty seat cushion trim cover unit. 2. Test the seat wire harness between the heated seat module connector and the 4-way heated seat wire harness connector for shorted or open circuits. If OK, (Refer to ELECTRONIC CONTROL MODULES/MEMORY HEATED SEAT/MIRROR MODULE - DIAGNOSIS AND TESTING). Also refer to the Body Diagnostic for additional diagnosis and testing procedures. If not OK, repair the shorted or open heated seat wire harness as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Heated Seat Element and Sensor Test > Page 6997 Seat Heater: Testing and Inspection Heated Seat System Heated Seat System Self- Diagnosis Chart SELF-DIAGNOSIS The heated seat system is capable of performing some self-diagnostics. The following table depicts the various failure modes which will be reported to the vehicle operator or technician by flashing the individual heated seat switch Light Emitting Diode (LED) indicator lamps. See the Heated Seat System Self-Diagnosis table for the diagnostic routines. The driver side heated seat switch indicator lamps will flash if a failure occurs in the driver side heated seat, and the passenger side heated seat switch indicator lamps will flash for a passenger side heated seat failure. If a monitored heated seat system failure occurs, the switch indicator lamps will flash at a pulse rate of about one-half second ON, followed by about one-half second OFF for a duration of about one minute after the switch for the faulty heated seat is depressed in either the Low or High direction. This process will repeat every time the faulty heated seat switch is actuated until the problem has been corrected. TESTING Refer to Power Seat for the location of complete heated seat system wiring diagrams. Before testing the individual components in the heated seat system, perform the following preliminary checks: WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - If the heated seat switch back lighting does not illuminate (Refer to HEATED SEATS/DRIVER HEATED SEAT SWITCH - DIAGNOSIS AND TESTING). - If a single indicator lamp for one heated seat switch does not operate and the heated seat elements do heat (Refer to HEATED SEATS/DRIVER HEATED SEAT SWITCH - DIAGNOSIS AND TESTING). - If both indicator lamps for a heated seat switch operate, but the heated seat elements do not heat, refer to Heated Seat Module in Electronic Control Modules for the location of the proper heated seat module diagnosis and testing procedures. Also refer to the Body Diagnostic for additional diagnosis and testing procedures. - If none of the indicator lamps for both heated seat switches will operate and the heated seat elements for both seats do not heat (Refer to ELECTRONIC CONTROL MODULES/MEMORY HEATED SEAT/MIRROR MODULE - DIAGNOSIS AND TESTING). - If the an indicator lamp on either heated seat switch remains illuminated after the heated seat has been turned OFF (Refer to ELECTRONIC CONTROL MODULES/MEMORY HEATED SEAT/MIRROR MODULE - DIAGNOSIS AND TESTING). Also refer to the Body Diagnostic for additional diagnosis and testing procedures. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Locations Seat Heater Control Module: Locations Fig. 8 Heated Seat Module - Typical The heated seat module is located under the heated seat switches, where it is secured to a mounting bracket that is also part of the center console. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Locations > Page 7001 Heated Seat Module Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Locations > Page 7002 Seat Heater Control Module: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Locations > Page 7003 Seat Heater Control Module: Description and Operation Fig. 8 Heated Seat Module - Typical HEATED SEAT MODULE Vehicles equipped with heated seats utilize a heated seat module. The heated seat module is located under the heated seat switches, where it is secured to a mounting bracket that is also part of the center console. The heated seat module has a single connector receptacle that allows the module to be connected to all of the required inputs and outputs through the center console wire harness. The heated seat module is an electronic microprocessor controlled device designed and programmed to use inputs from the ignition switch, the two heated seat switches and the two heated seat sensors to operate and control the heated seat elements in both front seats and the two heated seat indicator lamp Light-Emitting Diodes (LEDs) in each heated seat switch. The heated seat module is also programmed to perform self-diagnosis of certain heated seat system functions and provide feedback of that diagnosis through the heated seat switch indicator lamps. The heated seat module cannot be repaired. If the heated seat module is damaged or faulty, the entire module must be replaced. The heated seat module operates on fused battery current received from the ignition switch. The module is grounded at all times through a ground screw located on the drivers B-pillar. Inputs to the module include a resistor multiplexed heated seat switch request circuit for each of the two heated seat switches and the heated seat sensor inputs from the seat cushions of each front seat. In response to those inputs the heated seat module controls battery current feeds to the heated seat elements and sensors, and controls the ground for the heated seat switch indicator lamps. When a heated seat switch (Driver or Passenger) request signal is received by the heated seat module, the module energizes the proper indicator lamp (Low or High) in the switch by grounding the indicator lamp circuit to indicate that the heated seat system is operating. At the same time, the heated seat module energizes the selected heated seat sensor circuit and the sensor provides the module with an input indicating the surface temperature of the selected seat cushion. The Low heat set point is about 35 °C (100.4 °F), and the High heat set point is about 42 °C (107.6 °F). If the seat cushion surface temperature input is below the temperature set point for the selected temperature setting, the heated seat module energizes an N-channel Field Effect Transistor (N-FET) within the module which energizes the heated seat elements in the selected seat cushion and back. When the sensor input to the module indicates the correct temperature set point has been achieved, the module de-energizes the N-FET which de-energizes the heated seat elements. The heated seat module will continue to cycle the N-FET as needed to maintain the selected temperature set point. If the heated seat module detects a heated seat sensor value input that is out of range or a shorted or open heated seat element circuit, it will notify the vehicle operator or the repair technician of this condition by flashing the High and/or Low indicator lamps in the affected heated seat switch. Refer to Heated Seat System and Heated Seat Module in Electronic Control Modules for the location of the proper heated seat module diagnosis and testing procedures. Also refer to the Body Diagnostic for additional diagnosis and testing procedures. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Locations > Page 7004 Seat Heater Control Module: Testing and Inspection Refer to Wiring Diagrams in for the location of complete heated seat system wiring diagrams. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. If a heated seat fails to heat and one or both of the indicator lamps on a heated seat switch flash, refer to Heated Seat System in the Electrical for the location of the proper heated seat system diagnosis and testing procedures. If a heated seat heats but one or both indicator lamps on the heated seat switch fail to operate, test the heated seat switch. Refer to Heated Seat Switch in the heated seat for the location of the proper heated seat switch diagnosis and testing procedures. If the heated seat switch checks OK, go to Step 4. If both seats (driver and passenger) fail to heat and the indicator lamps on the heated seat switches for both seats fail to operate, test the ignition switch output circuit. If OK, go to Step 2 If not OK, repair the battery feed circuits to the heated seat switches. If only one seat (driver or passenger) fails to heat and the indicator lamps on the heated seat switch for that seat fail to operate, test that heated seat switch. Refer to Heated Seat Switch in the heated seat for the location of the proper heated seat switch diagnosis and testing procedures. If the heated seat switch checks OK, go to Step 3. If a heated seat switch indicator lamp remains illuminated after the heated seat has been turned OFF, go to Step 5. 2. Disconnect and isolate the battery negative cable. Disconnect the wire harness connector for the heated seat module from the heated seat module connector receptacle. Check for continuity between the ground circuit cavity of the wire harness connector for the heated seat module and a good ground. If not OK, repair the open ground circuit to ground as required. If OK, reconnect the battery negative cable. Turn the ignition switch to RUN position and check for battery voltage at the heated seat module connector receptacle. If OK, go to (3). If not OK, repair battery feed circuit to the heated seat module connector receptacle. 3. Turn the ignition switch to the OFF position. Disconnect the wire harness connector for the heated seat module from the heated seat module connector receptacle. Remove the heated seat switches from the center console. Disconnect the wire harness connector(s) from the connector receptacle(s) of the inoperative heated seat switch(es). Check for continuity between the inoperative driver and/or passenger heated seat switch circuit cavities of the heated seat switch wire harness connector(s) and the heated seat module wire harness connector. There should be continuity. If OK, replace the faulty heated seat module. If not OK, repair the open driver and/or passenger heated seat switch circuit as required. 4. Disconnect and isolate the battery negative cable. Disconnect the wire harness connector for the heated seat module from the heated seat module connector receptacle. Remove the heated seat switches from the center console. Check for continuity between the inoperative left and/or right seat high and/or low heat LED driver circuit cavities of the heated seat switch wire harness connector(s) and the heated seat module wire harness connector. There should be continuity. If OK, replace the faulty heated seat module. If not OK, repair the open left or right seat high or low heat LED driver circuit as required. 5. Disconnect and isolate the battery negative cable. Disconnect the wire harness connector for the heated seat module from the heated seat module connector receptacle. Remove the heated seat switches from the center console. Disconnect the center console wire harness connector(s) from the connector receptacle(s) of the heated seat switch(es) with the inaccurate indicator lamp(s). Check for continuity between the inoperative left and/or right seat high and/or low heat LED driver circuit cavity of the heated seat switch wire harness connector(s) and a good ground. There should be no continuity. If OK, replace the faulty heated seat module. If not OK, repair the shorted left or right seat high or low heat LED driver circuit as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Locations > Page 7005 Seat Heater Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the seat heater switches from the center console. Refer to the procedure in the Heated Seat. 3. Open the center console and remove the center console insert and floor mat, if equipped. 4. Using a long flat bladed screwdriver, insert the screwdriver through the heated switch mounting holes in the center console and depress the heated seat module mounting bracket retaining tabs. With the retaining tabs depressed reach into the center console and tilt the front wall of the console rearward. The heated seat module is now visible. 5. Remove the heated seat module from the mounting bracket by removing the retaining screws. 6. Disconnect the center console wire harness connector from the connector receptacle on the back of the heated seat module. 7. Remove the heated seat module from the vehicle. INSTALLATION 1. Position the heated seat module in the center console. 2. Connect the center console wire harness connector on the connector receptacle on the back of the heated seat module. 3. Install the heated seat module retaining screws. 4. Rotate the front center console wall up into position and install the center console insert and floor mat, if equipped. 5. Install the seat heater switches in the center console. Refer to the procedure in the heated seat. 6. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams Seat Heater Switch: Diagrams Driver Heated Seat Switch Passenger Heated Seat Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams > Page 7009 Seat Heater Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams > Page 7010 Seat Heater Switch: Description and Operation DRIVER SEAT HEATER SWITCH The heated seat switches used on vehicles with this option are both mounted in the center console. The two switches are snapped into mounting holes in the center console. The two heated seat switches are identical in appearance and construction, except for the location of a keyway in the single connector receptacle and the housing on the back of each switch. The instrument panel wire harness connectors for the heated seat switches are keyed to match the connector receptacles on the switches so that the two heated seat switches can only be connected to the proper heated seat. The momentary, bidirectional rocker-type heated seat switch provides a resistor-multiplexed signal to the heated seat module. Each switch has a center neutral position and momentary Low and High positions so that both the driver and the front seat passenger can select a preferred seat heating mode. Each heated seat switch has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected mode (Low or High) of the seat heater for each seat and to provide diagnostic feedback for the heated seat system. Each switch also has three other LED indicator lamps, which provides back lighting of the switch nomenclature when the ignition switch is in the Run position. The five LED indicator lamps in each heated seat switch cannot be repaired. If the indicator or back lighting lamps are faulty or damaged, the individual heated seat switch unit must be replaced. The heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the ON position. Depressing the heated seat switch rocker to its momentary High or Low position provides a hard-wired resistor multiplexed voltage request signal to the heated seat module to power the heated seat element of the selected seat and maintain the requested temperature setting. If the heated seat switch is depressed to a different position (Low or High) than the currently selected state, the heated seat module will change states to support the new selection. If a heated seat switch is depressed a second time to the same position as the currently selected state, the heated seat module interprets the second input as a request to turn the seat heater OFF. The heated seat module will then turn the heated seat elements for that seat OFF. The indicator lamps in the heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the ON position. The ground side of each indicator lamp is controlled by a separate (high or low/driver or passenger) indicator lamp driver circuit by the heated seat module. The heated seat module control of the switch indicator lamps also allows the module to provide diagnostic feedback to the vehicle operator to indicate monitored heated seat system faults by flashing the indicator lamps ON and OFF. One side of the back lighting LED's in each heated seat switch are connected in series to ground at all times. The other side of the LED's are connected to the ignition switch run circuit. These LED's are energized when the ignition switch is turned to the Run position. PASSENGER SEAT HEATER SWITCH The heated seat switches used on vehicles with this option are both mounted in the center console. The two switches are snapped into mounting holes in the center console. The two heated seat switches are identical in appearance and construction, except for the location of a keyway in the single connector receptacle and the housing on the back of each switch. The instrument panel wire harness connectors for the heated seat switches are keyed to match the connector receptacles on the switches so that the two heated seat switches can only be connected to the proper heated seat. The momentary, bidirectional rocker-type heated seat switch provides a resistor-multiplexed signal to the heated seat module. Each switch has a center neutral position and momentary Low and High positions so that both the driver and the front seat passenger can select a preferred seat heating mode. Each heated seat switch has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected mode (Low or High) of the seat heater for each seat and to provide diagnostic feedback for the heated seat system. Each switch also has three other LED indicator lamps, which provides back lighting of the switch nomenclature when the ignition switch is in the Run position. The five LED indicator lamps in each heated seat switch cannot be repaired. If the indicator or back lighting lamps are faulty or damaged, the individual heated seat switch unit must be replaced. The heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the ON position. Depressing the heated seat switch rocker to its momentary High or Low position provides a hard-wired resistor multiplexed voltage request signal to the heated seat module to power the heated seat element of the selected seat and maintain the requested temperature setting. If the heated seat switch is depressed to a different position (Low or High) than the currently selected state, the heated seat module will change states to support the new selection. If a heated seat switch is depressed a second time to the same position as the currently selected state, the heated seat module interprets the second input as a request to turn the seat heater OFF. The heated seat module will then turn the heated seat elements for that seat OFF. The indicator lamps in the heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the ON position. The ground side of each indicator lamp is controlled by a separate (high or low/driver or passenger) indicator lamp driver circuit by the heated seat module. The heated seat module control of the switch indicator lamps also allows the module to provide diagnostic feedback to the vehicle operator to indicate monitored heated seat system faults by flashing the indicator lamps ON and OFF. One side of the back lighting LED's in each heated seat switch are connected in series to ground at all times. The other side of the LED's are connected to the ignition switch run circuit. These LED's are energized when the ignition switch is turned to the Run position. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Testing and Inspection > Driver Heated Seat Switch Test Seat Heater Switch: Testing and Inspection Driver Heated Seat Switch Test WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. If the problem being diagnosed involves inoperative heated seat switch back lighting and the heated seat elements do heat, disconnect the inoperative switch and check for continuity between the ground pin at the heated seat switch connector and ground. If there is no continuity, repair an open wire between ground and the heated seat switch connector. If there is continuity, replace the inoperative heated seat switch with a known good unit. If the problem being diagnosed involves inoperative heated seat switch back lighting and the heated seat elements do not heat, refer to Step 2. If the problem being diagnosed involves inoperative heated seat switch indicator lamps and the heated seat elements do not heat, refer to Step 2. If the problem being diagnosed involves inoperative heated seat switch indicator lamps, inoperative back lighting and the heated seat elements do heat, go to Step 6. If the problem being diagnosed involves a heated seat switch indicator lamp that remains illuminated after the heated seat has been turned OFF, refer to Heated Seat Module in Electronic Control Modules for the location of the proper heated seat module diagnosis and testing procedures. Also refer to the Body Diagnostic for additional diagnosis and testing procedures. 2. Check the fused ignition switch output (run) fuse in the Junction Block (JB). If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 3. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run) fuse in the JB. If OK, go to Step 4. If not OK, repair the open fused ignition switch output (run) circuit to the ignition switch as required. 4. Disconnect and isolate the battery negative cable. Remove the heated seat switch from the center console. Disconnect the wire harness connector from the connector receptacle on the back of the heated seat switch to be tested. Reconnect the battery negative cable. Turn the ignition switch to the Run position. Check for battery voltage at the fused ignition switch output (run) circuit cavity of the center console wire harness connector for the heated seat switch. If OK, go to Step 5. If not OK, repair the open fused ignition switch output (run) circuit to the JB fuse as required. Heated Seat Switch Continuity Chart 5. Check the continuity and resistance values of the heated seat switch in the Neutral, Low and High positions as shown in the Heated Seat Switch Continuity chart. If OK, refer to Heated Seat Module in Electronic Control Modules for the location of the proper heated seat module diagnosis and testing procedures. Also refer to the Body Diagnostic for additional diagnosis and testing procedures. If not OK, replace the faulty heated seat switch. 6. Replace the inoperative heated seat switch with a known good unit and test the operation of the switch indicator lamps. If OK, discard the faulty heated seat switch. If not OK, refer to Heated Seat Module in Electronic Control Modules for the location of the proper heated seat module diagnosis and testing procedures. Also refer to the Body Diagnostic for additional diagnosis and testing procedures. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Testing and Inspection > Driver Heated Seat Switch Test > Page 7013 Seat Heater Switch: Testing and Inspection Passenger Heated Seat Switch Test WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. If the problem being diagnosed involves inoperative heated seat switch back lighting and the heated seat elements do heat, disconnect the inoperative switch and check for continuity between the ground pin at the heated seat switch connector and ground. If there is no continuity, repair an open wire between ground and the heated seat switch connector. If there is continuity, replace the inoperative heated seat switch with a known good unit. If the problem being diagnosed involves inoperative heated seat switch back lighting and the heated seat elements do not heat, refer to Step 2. If the problem being diagnosed involves inoperative heated seat switch indicator lamps and the heated seat elements do not heat, refer to Step 2. If the problem being diagnosed involves inoperative heated seat switch indicator lamps, inoperative back lighting and the heated seat elements do heat, go to Step 6. If the problem being diagnosed involves a heated seat switch indicator lamp that remains illuminated after the heated seat has been turned OFF, refer to Heated Seat Module in Electronic Control Modules for the location of the proper heated seat module diagnosis and testing procedures. Also refer to the Body Diagnostic for additional diagnosis and testing procedures. 2. Check the fused ignition switch output (run) fuse in the Junction Block (JB). If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 3. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run) fuse in the JB. If OK, go to Step 4. If not OK, repair the open fused ignition switch output (run) circuit to the ignition switch as required. 4. Disconnect and isolate the battery negative cable. Remove the heated seat switch from the center console. Disconnect the wire harness connector from the connector receptacle on the back of the heated seat switch to be tested. Reconnect the battery negative cable. Turn the ignition switch to the Run position. Check for battery voltage at the fused ignition switch output (run) circuit cavity of the center console wire harness connector for the heated seat switch. If OK, go to Step 5. If not OK, repair the open fused ignition switch output (run) circuit to the JB fuse as required. Heated Seat Switch Continuity Chart 5. Check the continuity and resistance values of the heated seat switch in the Neutral, Low and High positions as shown in the Heated Seat Switch Continuity chart. If OK, refer to Heated Seat Module in Electronic Control Modules for the location of the proper heated seat module diagnosis and testing procedures. Also refer to the Body Diagnostic for additional diagnosis and testing procedures. If not OK, replace the faulty heated seat switch. 6. Replace the inoperative heated seat switch with a known good unit and test the operation of the switch indicator lamps. If OK, discard the faulty heated seat switch. If not OK, refer to Heated Seat Module in Electronic Control Modules for the location of the proper heated seat module diagnosis and testing procedures. Also refer to the Body Diagnostic for additional diagnosis and testing procedures. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Driver Heated Seat Switch Replacement Seat Heater Switch: Service and Repair Driver Heated Seat Switch Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a small flat bladed pry tool, gently pry the lower right side edge of the seat heater switch out of its mounting location in the center console. 3. Pull the heated seat switch out far enough to access and disconnect the center console wire harness connector from the connector receptacle on the back of the heated seat switch. 4. Remove the heated seat switch from the center console. INSTALLATION 1. Connect the center console wire harness connector on the connector receptacle on the back of the heated seat switch. 2. Install the heated seat switch in the center console mounting hole. 3. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Driver Heated Seat Switch Replacement > Page 7016 Seat Heater Switch: Service and Repair Passenger Heated Seat Switch Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a small flat bladed pry tool, gently pry the lower right side edge of the seat heater switch out of its mounting location in the center console. 3. Pull the heated seat switch out far enough to access and disconnect the center console wire harness connector from the connector receptacle on the back of the heated seat switch. 4. Remove the heated seat switch from the center console. INSTALLATION 1. Connect the center console wire harness connector on the connector receptacle on the back of the heated seat switch. 2. Install the heated seat switch in the center console mounting hole. 3. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Description and Operation Seat Heater Thermostat: Description and Operation HEATED SEAT ELEMENT & SENSOR One end of the heated seat element resistor wire is connected to a ground feed at all times through a splice in the heated seat module ground circuit. Battery current is directed to the other end of the heated seat element resistor wire by the energized N-channel Field Effect Transistor (N-FET) located within the heated seat module. The heated seat module will energize the N-FET only when the heated seat switch is in the Low or High position and the heated seat sensor indicates that the seat cushion surface temperature is below the selected (Low or High) temperature set point. As electrical current passes through the heating element grid, the resistance of the wire used in the element disperses some of that electrical current in the form of heat. The heat produced by the heated seat element grid then radiates through the underside of the seat cushion and seat back trim covers, warming the seat cover and its occupant. The resistance of the heated seat sensor increases and decreases as the surface temperature of the seat cushion cover changes. The heated seat module supplies each sensor with a voltage feed, then detects the sensor resistance by monitoring the voltage of the separate sensor return circuits. The heated seat module compares the heated seat sensor resistance (seat cushion surface temperature) with the heated seat switch resistance (Low or High set point) to determine when the heated seat element grids need to be cycled ON or OFF in order to maintain the selected temperature set point. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Description and Operation > Page 7020 Seat Heater Thermostat: Testing and Inspection The heated seat module will self-diagnose shorted or open heated seat element circuits and the sensor circuits. Refer to Heated Seat System for the location of the proper heated seat system diagnosis and testing procedures. To manually check the heated seat element and sensor circuits, proceed as follows. The wire harness connectors for the seat cushion heated seat element and sensor and for the seat back heated seat element are located under the seat, near the rear edge of the seat cushion frame. Heated Seat Element 1. Disconnect and isolate the battery negative cable. Disconnect the 4-way heated seat wire harness connector. Check for continuity between the two heated seat element circuit cavities in the seat cushion trim cover half of the 4-way heated seat wire harness connector. There should be continuity. If OK, go to Step 2. If not OK, go to Step 3. 2. Check for continuity between one of the heated seat element circuit cavities in the seat cushion trim cover half of the 4-way heated seat wire harness connector and the seat cushion frame. There should be no continuity. If OK, go to Step 5. If not OK, go to Step 4. 3. Disconnect the 2-way heated seat wire harness connector between the seat cushion trim cover and the seat back trim cover. Check for continuity between the heated seat element circuit cavity and the ground circuit cavity in the seat back trim cover half of the 2-way heated seat wire harness connector. There should be continuity. If OK, go to Step 5. If not OK, replace the faulty seat back trim cover unit. 4. Check for continuity between the heated seat element circuit cavity in the seat back trim cover half of the 2-way heated seat wire harness connector and the seat back frame. There should be no continuity. If OK, go to Step 5. If not OK, replace the faulty seat back trim cover unit. 5. Test the seat wire harness between the heated seat module connector and the 4-way heated seat wire harness connectors for shorted or open circuits. If OK, replace the faulty seat cushion trim cover unit. If not OK, repair the shorted or open seat wire harness as required. Heated Seat Sensor 1. Disconnect and isolate the battery negative cable. Disconnect the 4-way heated seat wire harness connector. Using an ohmmeter, check the resistance between the heated seat sensor input circuit cavity and the heated seat sensor feed circuit cavity in the seat cushion cover half of the 4-way heated seat wire harness connector. The heated seat sensor resistance should be between 600 ohms and 200 kilo ohms. If OK, go to Step 2. If not OK, replace the faulty seat cushion trim cover unit. 2. Test the seat wire harness between the heated seat module connector and the 4-way heated seat wire harness connector for shorted or open circuits. If OK, (Refer to ELECTRONIC CONTROL MODULES/MEMORY HEATED SEAT/MIRROR MODULE - DIAGNOSIS AND TESTING). Also refer to the Body Diagnostic for additional diagnosis and testing procedures. If not OK, repair the shorted or open heated seat wire harness as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Description and Operation Seat Track: Description and Operation There are three reversible motors that operate the power seat adjuster. The motors are connected to worm-drive gearboxes that move the seat adjuster through a combination of screw-type drive units. The front and rear of a seat are operated by different motors. They can be raised or lowered independently of each other. When the center seat switch is pushed in the Up or Down direction, both the front and rear motors operate in unison. The forward-rear-ward motor is operated by pushing the center seat switch in the Forward or Rearward direction, which moves the entire seat in the selected direction on all models. Each motor contains a self-resetting circuit breaker to protect it from overload. Consecutive or frequent resetting of the circuit breakers must not be allowed to continue, or the motors may be damaged. Make the necessary repairs. The power seat adjuster and motors cannot be repaired, and are serviced only as a complete unit. If any component in this unit is faulty or damaged, the entire power seat adjuster and motors assembly must be replaced. When a power seat switch is actuated, a battery feed and a ground path are applied through the power seat switch contacts to the appropriate motor or motors. The motor and drive unit operate to move the seat in the selected direction until the switch is released, or until the travel limit of the power seat track is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor is reversed through the switch contacts. This causes the motor to run in the opposite direction. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Description and Operation > Page 7024 Seat Track: Testing and Inspection Operate the power seat switch to move all three seat motors in each direction. The seat should move in each of the selected directions. If the power seat track fails to operate in only one direction, move the seat track a short distance in the opposite direction and test again to be certain that the track is not at its travel limit. If the power seat track still fails to operate in only one direction, refer to Diagnosis and Testing of the Power Seat Switch. If the power seat track fails to operate in more than one direction, proceed as follows: 1. Check the power seat fuse in the power distribution center. If OK, go to Step 2. If not OK, replace the faulty fuse. 2. Remove the power seat switch from the seat. Check for battery voltage at the fused B(+) circuit cavity of the power seat switch wire harness connector. If OK, go to Step 3. If not OK, repair the open circuit to the power distribution center as required. 3. Check for continuity between the ground circuit cavity of the power seat switch wire harness connector and a good ground. There should be continuity. If OK, go to Step 4. If not OK, repair the open circuit to ground as required. 4. Test the power seat switch as described. If the switch tests OK, check the wire harness between the power seat switch and the motor for shorts or opens. If the circuits check OK, replace the faulty power seat track (adjuster) assembly. If the circuits are not OK, repair the wire harness as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Description and Operation > Page 7025 Seat Track: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the seat, power seat track from the vehicle as a unit. Refer to Body for the procedure. 3. Unplug the power seat wire harness connectors at each of the three power seat motors. 4. Release the power seat wire harness retainers from the seat track. 5. Remove the fasteners that secure the center seat cushion to the brackets on the power seat track. 6. Remove the screws that secure the power seat track assembly to the seat cushion frame. 7. Remove the power seat track assembly from the seat cushion frame. INSTALLATION 1. Position the power seat track assembly on the seat cushion frame. 2. Install the fasteners that secure the center seat cushion to the brackets on the power seat adjuster. 3. Install the screws that secure the power seat track assembly to the seat cushion frame. 4. Connect the power seat wire harness connectors at each of the three power seat motors. 5. Install the power seat wire harness retainers on the seat track assembly. 6. Install the seat, power seat track as a unit. Refer to Body for the procedure. 7. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams Passenger Door Power Lock Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 7030 Power Door Lock Switch: Description and Operation The power lock system can be controlled by a two way, momentary, resistor multiplexed, single gang switch on a power lock and window switch bezel located near the forward end of the armrest on the passenger side front door trim panel. The power lock switch on the driver side front door trim panel is integral to the driver door module. (Refer to POWER LOCKS/DRIVER DOOR MODULE DESCRIPTION). The power lock switch is secured by integral latch tabs in a molded plastic receptacle on the back side of the power window and lock switch bezel so that only the switch paddle is visible where it protrudes through the bezel. The power window and lock switch bezel is secured by small metal snap clips within an opening near the forward end of the arm rest in the passenger side front door trim panel so that the switches can be serviced without removing the front door trim panel. An integral connector receptacle on the back of the switch connects it to the vehicle electrical system through a take out and connector of the right front door wire harness. The power lock switch has a green Light-Emitting Diode (LED) located in the switch paddle to improve switch visibility in dark ambient lighting conditions. The power lock switch cannot be adjusted or repaired and, if faulty or damaged, the switch unit must be replaced. The two-way, momentary, power lock switch on the passenger side front door is connected in series between ground and the passenger door switch mux input of the Central Timer Module (CTM). The power lock switch on the driver side front door trim panel is integral to the driver door module. (Refer to POWER LOCKS/DRIVER DOOR MODULE - OPERATION). Each power lock switch position Lock, Unlock, and Neutral provides a different resistance value to the CTM input which allows the CTM to sense the switch position. Based upon the power lock switch inputs, the CTM controls the battery and ground feed outputs to the power lock motors to lock or unlock the door and liftgate latches. The Light-Emitting Diode (LED) in the paddle of the passenger door power lock switch is connected to battery current through a fuse in the Junction Block (JB) on a fused ignition switch output (run) circuit; therefore, the switch will only be illuminated when the ignition switch is in the On position. The power lock switch can be diagnosed using conventional diagnostic tools and methods. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 7031 Power Door Lock Switch: Testing and Inspection The Light-Emitting Diode (LED) illumination lamp of the power lock switch receives battery current through a fuse in the Junction Block (JB) on a fused ignition switch output (run) circuit. The power lock switch on the driver side front door trim panel is integral to the driver door module. (Refer to POWER LOCKS/DRIVER DOOR MODULE - DIAGNOSIS AND TESTING). If the power lock switch operates, but the LED is inoperative, check for battery current at the switch with the ignition switch in the ON position. If OK, replace the faulty switch. 1. Disconnect and isolate the battery negative cable. Remove the power lock switch from the door trim panel. Disconnect the door wire harness connector for the power lock switch from the switch connector receptacle. Power Lock Switch Test Fig.5 Powr Lock Switch Connector Receptable 2. Test the power lock switch resistance. See the Power Lock Switch Test chart to determine if the resistance is correct for the switch in each switch position. If not OK, replace the faulty power lock switch as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 7032 Power Door Lock Switch: Service and Repair REMOVAL The power lock switch on the driver side front door trim panel is integral to the driver door module. (Refer to POWER LOCKS/DRIVER DOOR MODULE - REMOVAL). 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick or another suitable wide flat bladed tool and starting at the rear of the passenger door power window and lock switch bezel, gently pry the bezel up and out from the passenger side front door trim panel. 3. Pull the power window and lock switch bezel away from the trim panel opening far enough to access the two switch connector receptacles on the back of the unit. 4. Disconnect the door wire harness connectors for the power lock and power window switches from the switch connector receptacles. 5. Remove the power window and lock switch bezel from the door trim panel. 6. Using a small thin-bladed screwdriver, gently pry the snap clips at the sides of the power lock switch receptacle on the back of the power window and lock switch bezel and pull the switch out of the receptacle. INSTALLATION The power lock switch on the driver side front door trim panel is integral to the driver door module. (Refer to POWER LOCKS/DRIVER DOOR MODULE - INSTALLATION). 1. Align the power lock switch with the receptacle on the back of the power window and lock switch bezel. 2. Using hand pressure, gently and evenly press down on the power lock switch it snaps into place in the power window and lock switch bezel receptacle. 3. Position the power window and lock switch bezel to the opening in the passenger side front door trim panel. 4. Reconnect the two door wire harness connectors for the power window and power lock switches to the switch connector receptacles. 5. Insert the front of the power window and lock switch bezel into the opening in the passenger side front door trim panel. 6. Using hand pressure, gently and evenly press down on the rear of the power window and lock switch bezel until it snaps into place. 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection Power Mirror Switch: Testing and Inspection The power mirror switch is included with the Driver Door Module. (Refer to DOOR MODULE DIAGNOSIS AND TESTING) for service procedures. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Page 7036 Power Mirror Switch: Service and Repair REMOVAL The power mirror switch is included with the Driver Door Module. (Refer to DOOR MODULE REMOVAL) for service procedures. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations Power Seat Switch: Locations The switch is located on the lower outboard side of the seat cushion on the seat cushion side shield on all models. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 7040 Power Seat Switch: Diagrams Driver Power Seat Switch Passenger Power Seat Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 7041 Power Seat Switch: Description and Operation DRIVER POWER SEAT SWITCH The power seat can be adjusted in six different ways using the power seat switch. The power seat switch for some models has an additional switch knob for adjusting the power lumbar support. The switch is located on the lower outboard side of the seat cushion on the seat cushion side shield on all models. Refer to the owner's manual in the vehicle glove box for more information on the power seat switch functions and the seat adjusting procedures. The individual switches in the power seat switch module cannot be repaired. If one switch is damaged or faulty, the entire power seat switch module must be replaced. When a power switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track or recliner adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. PASSENGER POWER SEAT SWITCH The power seat can be adjusted in six different ways using the power seat switch. The power seat switch for some models has an additional switch knob for adjusting the power lumbar support. The switch is located on the lower outboard side of the seat cushion on the seat cushion side shield on all models. Refer to the owner's manual in the vehicle glove box for more information on the power seat switch functions and the seat adjusting procedures. The individual switches in the power seat switch module cannot be repaired. If one switch is damaged or faulty, the entire power seat switch module must be replaced. When a power switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track or recliner adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver Power Seat Switch Test Power Seat Switch: Testing and Inspection Driver Power Seat Switch Test 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat. Driver Power Seat Switch Test Fig. 1 Driver Seat Switch 3. Use an ohmmeter to test the continuity of the power seat switches in each position. See the Power Seat Switch Continuity chart and figure. If OK, see Power Seat Adjuster and Motors or Power Lumbar Adjuster and Motor in the Diagnosis and Testing. If not OK, replace the faulty power seat switch unit. CAUTION: Be certain the two halves of the power seat switch assembly are completely snapped together. Failure to do so could result in a misdiagnosed power seat switch. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver Power Seat Switch Test > Page 7044 Power Seat Switch: Testing and Inspection Passenger Power Seat Switch Test 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat. Passenger Power Seat Switch Test Fig. 2 Passenger Power Seat Switch 3. Use an ohmmeter to test the continuity of the power seat switches in each position. See the Power Seat Switch Continuity chart and figure. If OK, see Power Seat Adjuster and Motors or Power Lumbar Adjuster and Motor in the Diagnosis and Testing. If not OK, replace the faulty power seat switch unit. CAUTION: Be certain the two halves of the power seat switch assembly are completely snapped together. Failure to do so could result in a misdiagnosed power seat switch. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Driver Power Seat Switch Replacement Power Seat Switch: Service and Repair Driver Power Seat Switch Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the seat cushion side shield from the seat. Refer to Body for the procedure. 3. Pull the switch bezel or side shield unit out from the seat far enough to access the switch wire harness connector. Gently pry the locking tabs of the switch away from the wire harness connector and carefully unplug the connector from the power seat switch module. 4. Remove the screws that secure the power seat switch. INSTALLATION 1. Position the power seat switch on the seat cushion side shield and connect the electrical connector. 2. Install the screws that secure the power seat switch to seat cushion side shield. 3. Install the seat cushion side shield on the seat. Refer to Body for the procedure. 4. If equipped, install the recliner lever on the recliner mechanism release shaft. 5. If equipped, install the screw that secures the recliner lever to the recliner mechanism release shaft on the outboard side of the front seat. 6. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Driver Power Seat Switch Replacement > Page 7047 Power Seat Switch: Service and Repair Passenger Power Seat Switch Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the seat cushion side shield from the seat. Refer to Body for the procedure. 3. Pull the switch bezel or side shield unit out from the seat far enough to access the switch wire harness connector. Gently pry the locking tabs of the switch away from the wire harness connector and carefully unplug the connector from the power seat switch module. 4. Remove the screws that secure the power seat switch. INSTALLATION 1. Position the power seat switch on the seat cushion side shield and connect the electrical connector. 2. Install the screws that secure the power seat switch to seat cushion side shield. 3. Install the seat cushion side shield on the seat. Refer to Body for the procedure. 4. If equipped, install the recliner lever on the recliner mechanism release shaft. 5. If equipped, install the screw that secures the recliner lever to the recliner mechanism release shaft on the outboard side of the front seat. 6. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams Seat Heater Switch: Diagrams Driver Heated Seat Switch Passenger Heated Seat Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Page 7051 Seat Heater Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Page 7052 Seat Heater Switch: Description and Operation DRIVER SEAT HEATER SWITCH The heated seat switches used on vehicles with this option are both mounted in the center console. The two switches are snapped into mounting holes in the center console. The two heated seat switches are identical in appearance and construction, except for the location of a keyway in the single connector receptacle and the housing on the back of each switch. The instrument panel wire harness connectors for the heated seat switches are keyed to match the connector receptacles on the switches so that the two heated seat switches can only be connected to the proper heated seat. The momentary, bidirectional rocker-type heated seat switch provides a resistor-multiplexed signal to the heated seat module. Each switch has a center neutral position and momentary Low and High positions so that both the driver and the front seat passenger can select a preferred seat heating mode. Each heated seat switch has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected mode (Low or High) of the seat heater for each seat and to provide diagnostic feedback for the heated seat system. Each switch also has three other LED indicator lamps, which provides back lighting of the switch nomenclature when the ignition switch is in the Run position. The five LED indicator lamps in each heated seat switch cannot be repaired. If the indicator or back lighting lamps are faulty or damaged, the individual heated seat switch unit must be replaced. The heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the ON position. Depressing the heated seat switch rocker to its momentary High or Low position provides a hard-wired resistor multiplexed voltage request signal to the heated seat module to power the heated seat element of the selected seat and maintain the requested temperature setting. If the heated seat switch is depressed to a different position (Low or High) than the currently selected state, the heated seat module will change states to support the new selection. If a heated seat switch is depressed a second time to the same position as the currently selected state, the heated seat module interprets the second input as a request to turn the seat heater OFF. The heated seat module will then turn the heated seat elements for that seat OFF. The indicator lamps in the heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the ON position. The ground side of each indicator lamp is controlled by a separate (high or low/driver or passenger) indicator lamp driver circuit by the heated seat module. The heated seat module control of the switch indicator lamps also allows the module to provide diagnostic feedback to the vehicle operator to indicate monitored heated seat system faults by flashing the indicator lamps ON and OFF. One side of the back lighting LED's in each heated seat switch are connected in series to ground at all times. The other side of the LED's are connected to the ignition switch run circuit. These LED's are energized when the ignition switch is turned to the Run position. PASSENGER SEAT HEATER SWITCH The heated seat switches used on vehicles with this option are both mounted in the center console. The two switches are snapped into mounting holes in the center console. The two heated seat switches are identical in appearance and construction, except for the location of a keyway in the single connector receptacle and the housing on the back of each switch. The instrument panel wire harness connectors for the heated seat switches are keyed to match the connector receptacles on the switches so that the two heated seat switches can only be connected to the proper heated seat. The momentary, bidirectional rocker-type heated seat switch provides a resistor-multiplexed signal to the heated seat module. Each switch has a center neutral position and momentary Low and High positions so that both the driver and the front seat passenger can select a preferred seat heating mode. Each heated seat switch has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected mode (Low or High) of the seat heater for each seat and to provide diagnostic feedback for the heated seat system. Each switch also has three other LED indicator lamps, which provides back lighting of the switch nomenclature when the ignition switch is in the Run position. The five LED indicator lamps in each heated seat switch cannot be repaired. If the indicator or back lighting lamps are faulty or damaged, the individual heated seat switch unit must be replaced. The heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the ON position. Depressing the heated seat switch rocker to its momentary High or Low position provides a hard-wired resistor multiplexed voltage request signal to the heated seat module to power the heated seat element of the selected seat and maintain the requested temperature setting. If the heated seat switch is depressed to a different position (Low or High) than the currently selected state, the heated seat module will change states to support the new selection. If a heated seat switch is depressed a second time to the same position as the currently selected state, the heated seat module interprets the second input as a request to turn the seat heater OFF. The heated seat module will then turn the heated seat elements for that seat OFF. The indicator lamps in the heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the ON position. The ground side of each indicator lamp is controlled by a separate (high or low/driver or passenger) indicator lamp driver circuit by the heated seat module. The heated seat module control of the switch indicator lamps also allows the module to provide diagnostic feedback to the vehicle operator to indicate monitored heated seat system faults by flashing the indicator lamps ON and OFF. One side of the back lighting LED's in each heated seat switch are connected in series to ground at all times. The other side of the LED's are connected to the ignition switch run circuit. These LED's are energized when the ignition switch is turned to the Run position. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Testing and Inspection > Driver Heated Seat Switch Test Seat Heater Switch: Testing and Inspection Driver Heated Seat Switch Test WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. If the problem being diagnosed involves inoperative heated seat switch back lighting and the heated seat elements do heat, disconnect the inoperative switch and check for continuity between the ground pin at the heated seat switch connector and ground. If there is no continuity, repair an open wire between ground and the heated seat switch connector. If there is continuity, replace the inoperative heated seat switch with a known good unit. If the problem being diagnosed involves inoperative heated seat switch back lighting and the heated seat elements do not heat, refer to Step 2. If the problem being diagnosed involves inoperative heated seat switch indicator lamps and the heated seat elements do not heat, refer to Step 2. If the problem being diagnosed involves inoperative heated seat switch indicator lamps, inoperative back lighting and the heated seat elements do heat, go to Step 6. If the problem being diagnosed involves a heated seat switch indicator lamp that remains illuminated after the heated seat has been turned OFF, refer to Heated Seat Module in Electronic Control Modules for the location of the proper heated seat module diagnosis and testing procedures. Also refer to the Body Diagnostic for additional diagnosis and testing procedures. 2. Check the fused ignition switch output (run) fuse in the Junction Block (JB). If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 3. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run) fuse in the JB. If OK, go to Step 4. If not OK, repair the open fused ignition switch output (run) circuit to the ignition switch as required. 4. Disconnect and isolate the battery negative cable. Remove the heated seat switch from the center console. Disconnect the wire harness connector from the connector receptacle on the back of the heated seat switch to be tested. Reconnect the battery negative cable. Turn the ignition switch to the Run position. Check for battery voltage at the fused ignition switch output (run) circuit cavity of the center console wire harness connector for the heated seat switch. If OK, go to Step 5. If not OK, repair the open fused ignition switch output (run) circuit to the JB fuse as required. Heated Seat Switch Continuity Chart 5. Check the continuity and resistance values of the heated seat switch in the Neutral, Low and High positions as shown in the Heated Seat Switch Continuity chart. If OK, refer to Heated Seat Module in Electronic Control Modules for the location of the proper heated seat module diagnosis and testing procedures. Also refer to the Body Diagnostic for additional diagnosis and testing procedures. If not OK, replace the faulty heated seat switch. 6. Replace the inoperative heated seat switch with a known good unit and test the operation of the switch indicator lamps. If OK, discard the faulty heated seat switch. If not OK, refer to Heated Seat Module in Electronic Control Modules for the location of the proper heated seat module diagnosis and testing procedures. Also refer to the Body Diagnostic for additional diagnosis and testing procedures. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Testing and Inspection > Driver Heated Seat Switch Test > Page 7055 Seat Heater Switch: Testing and Inspection Passenger Heated Seat Switch Test WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. If the problem being diagnosed involves inoperative heated seat switch back lighting and the heated seat elements do heat, disconnect the inoperative switch and check for continuity between the ground pin at the heated seat switch connector and ground. If there is no continuity, repair an open wire between ground and the heated seat switch connector. If there is continuity, replace the inoperative heated seat switch with a known good unit. If the problem being diagnosed involves inoperative heated seat switch back lighting and the heated seat elements do not heat, refer to Step 2. If the problem being diagnosed involves inoperative heated seat switch indicator lamps and the heated seat elements do not heat, refer to Step 2. If the problem being diagnosed involves inoperative heated seat switch indicator lamps, inoperative back lighting and the heated seat elements do heat, go to Step 6. If the problem being diagnosed involves a heated seat switch indicator lamp that remains illuminated after the heated seat has been turned OFF, refer to Heated Seat Module in Electronic Control Modules for the location of the proper heated seat module diagnosis and testing procedures. Also refer to the Body Diagnostic for additional diagnosis and testing procedures. 2. Check the fused ignition switch output (run) fuse in the Junction Block (JB). If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 3. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run) fuse in the JB. If OK, go to Step 4. If not OK, repair the open fused ignition switch output (run) circuit to the ignition switch as required. 4. Disconnect and isolate the battery negative cable. Remove the heated seat switch from the center console. Disconnect the wire harness connector from the connector receptacle on the back of the heated seat switch to be tested. Reconnect the battery negative cable. Turn the ignition switch to the Run position. Check for battery voltage at the fused ignition switch output (run) circuit cavity of the center console wire harness connector for the heated seat switch. If OK, go to Step 5. If not OK, repair the open fused ignition switch output (run) circuit to the JB fuse as required. Heated Seat Switch Continuity Chart 5. Check the continuity and resistance values of the heated seat switch in the Neutral, Low and High positions as shown in the Heated Seat Switch Continuity chart. If OK, refer to Heated Seat Module in Electronic Control Modules for the location of the proper heated seat module diagnosis and testing procedures. Also refer to the Body Diagnostic for additional diagnosis and testing procedures. If not OK, replace the faulty heated seat switch. 6. Replace the inoperative heated seat switch with a known good unit and test the operation of the switch indicator lamps. If OK, discard the faulty heated seat switch. If not OK, refer to Heated Seat Module in Electronic Control Modules for the location of the proper heated seat module diagnosis and testing procedures. Also refer to the Body Diagnostic for additional diagnosis and testing procedures. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Driver Heated Seat Switch Replacement Seat Heater Switch: Service and Repair Driver Heated Seat Switch Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a small flat bladed pry tool, gently pry the lower right side edge of the seat heater switch out of its mounting location in the center console. 3. Pull the heated seat switch out far enough to access and disconnect the center console wire harness connector from the connector receptacle on the back of the heated seat switch. 4. Remove the heated seat switch from the center console. INSTALLATION 1. Connect the center console wire harness connector on the connector receptacle on the back of the heated seat switch. 2. Install the heated seat switch in the center console mounting hole. 3. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Driver Heated Seat Switch Replacement > Page 7058 Seat Heater Switch: Service and Repair Passenger Heated Seat Switch Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a small flat bladed pry tool, gently pry the lower right side edge of the seat heater switch out of its mounting location in the center console. 3. Pull the heated seat switch out far enough to access and disconnect the center console wire harness connector from the connector receptacle on the back of the heated seat switch. 4. Remove the heated seat switch from the center console. INSTALLATION 1. Connect the center console wire harness connector on the connector receptacle on the back of the heated seat switch. 2. Install the heated seat switch in the center console mounting hole. 3. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams Liftgate Ajar Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Page 7062 Trunk / Liftgate Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Page 7063 Trunk / Liftgate Switch: Description and Operation LIFTGATE AJAR SWITCH The liftgate ajar switch is integral to the latch on the liftgate. The switch closes a path to ground for the Central Timer Module (CTM) when the liftgate is opened, and opens the ground path when the liftgate is closed. The liftgate ajar switch cannot be repaired and, if faulty or damaged, the liftgate latch unit must be replaced. The liftgate ajar switch closes a path to ground for the Central Timer Module (CTM) when the liftgate is opened, and opens the ground path when the liftgate is closed. The liftgate ajar switch is connected in series between ground and the CTM to provide a unique input. The CTM reads the switch status through an internal pull-up, then sends the proper switch status messages to other electronic modules over the Programmable Communications Interface (PCI) data bus network. The liftgate ajar switch can be diagnosed using conventional diagnostic tools and methods. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Page 7064 Trunk / Liftgate Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Disconnect the liftgate latch pigtail wire connector from the liftgate wire harness connector. Check for continuity between the ground circuit cavity in the liftgate wire harness connector and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the open ground circuit to ground as required. 2. Check for continuity between the ground circuit cavity and the liftgate ajar switch sense circuit cavity in the liftgate latch pigtail wire connector. There should be continuity with the liftgate opened, and no continuity with the liftgate closed. If OK, go to Step 3. If not OK, replace the faulty liftgate latch unit. 3. Disconnect the body wire harness connector (Connector C2) for the Central Timer Module (CTM) from the CTM connector receptacle. Check for continuity between the liftgate ajar switch sense circuit cavity of the body wire harness connector (Connector C2) and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, repair the shorted liftgate ajar switch sense circuit between the liftgate latch and the CTM as required. 4. Check for continuity between the liftgate ajar switch sense circuit cavities of the body wire harness connector (Connector C2) and the liftgate wire harness connector for the liftgate latch. There should be continuity. If OK, use a DRB III scan tool to diagnose the CTM. Refer to the appropriate diagnostic procedures. If not OK, repair the open liftgate ajar switch sense circuit between the liftgate latch and the CTM as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Tailgate Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks - Intermittently Lock/Unlock by Themselves Tailgate Lock Cylinder: Customer Interest Power Locks - Intermittently Lock/Unlock by Themselves NUMBER: 08-023-03 GROUP: Electrical DATE: July 18, 2003 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-041-00, DATED DEC. 15, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THE REVISION ADDS 2002 AND 2003 VEHICLES AND REVISES THE PARTS TABLE. SUBJECT: Intermittent Locking/Unlocking Of Doors Without Activating The Power Door Lock Switch OVERVIEW: This bulletin involves installing new door/liftgate lock cylinder switches. MODELS: **2000 - 2003** (AB) Ram Van/Wagon **2000 - 2003** (AN) Dakota **2000 - 2002** (BR/BE) Ram Truck **2000 - 2003** (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH VEHICLE THEFT SECURITY SYSTEM (SALES CODE LSA). SYMPTOM/CONDITION: The door locks will intermittently lock and/or unlock without any activation of the power door lock switch or a clicking sound may be heard coming from the power door locks (repeated locking or repeated unlocking). The condition may occur more frequently in damp conditions such as driving the vehicle in the rain or taking the vehicle through a car wash. DIAGNOSIS: Vehicles that demonstrate this condition may have water weeping into the door/liftgate lock cylinder switches causing the switch to intermittently short across the internal circuit. This in turn may signal the Central Timer Module (CTM) to activate the power door locks. Because of the nature of this problem, it is extremely difficult to diagnose this condition. Therefore, customers that indicate their doors intermittently lock and unlock without having the door lock switch activated or customers that indicate they hear a repeated clicking noise coming from the door locks should have the Repair Procedure performed on their vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Tailgate Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks - Intermittently Lock/Unlock by Themselves > Page 7074 PARTS REQUIRED: NOTE: **The passenger side door lock cylinder switch has been eliminated on 2002 and 2003 Durangos and on 2003 Dakotas built after April 7, 2003 (MDH 0407XX)**. REPAIR PROCEDURE: 1. Remove the driver, passenger (if equipped), and liftgate (Durango only) door lock cylinder switches. Refer to the appropriate Service Manual Group 8Q, pages 8QA and 8Q-5 or the service information available in the MDS2 for DOOR LOCK CYLINDER SWITCH and/or LIFTGATE LOCK CYLINDER SWITCH - REMOVAL AND INSTALLATION procedures. 2. The door lock cylinder switch actuator must be positioned in its neutral position prior to installing the new switch on the lock cylinder. Rotate the actuator until the actuator is positioned as shown in the following figure (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Tailgate Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks - Intermittently Lock/Unlock by Themselves > Page 7075 3. Install the driver, passenger (if equipped), and liftgate (Durango only) door lock cylinder switches. Refer to the appropriate Service Manual Group 8Q, pages 8QA and 8Q-5 or the service information available in the MDS2 for DOOR LOCK CYLINDER SWITCH and/or LIFTGATE LOCK CYLINDER SWITCH - REMOVAL AND INSTALLATION procedures. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Tailgate Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks - Intermittently Lock/Unlock by Themselves > Page 7076 FAILURE CODE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks Intermittently Lock/Unlock by Themselves Tailgate Lock Cylinder: All Technical Service Bulletins Power Locks - Intermittently Lock/Unlock by Themselves NUMBER: 08-023-03 GROUP: Electrical DATE: July 18, 2003 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-041-00, DATED DEC. 15, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THE REVISION ADDS 2002 AND 2003 VEHICLES AND REVISES THE PARTS TABLE. SUBJECT: Intermittent Locking/Unlocking Of Doors Without Activating The Power Door Lock Switch OVERVIEW: This bulletin involves installing new door/liftgate lock cylinder switches. MODELS: **2000 - 2003** (AB) Ram Van/Wagon **2000 - 2003** (AN) Dakota **2000 - 2002** (BR/BE) Ram Truck **2000 - 2003** (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH VEHICLE THEFT SECURITY SYSTEM (SALES CODE LSA). SYMPTOM/CONDITION: The door locks will intermittently lock and/or unlock without any activation of the power door lock switch or a clicking sound may be heard coming from the power door locks (repeated locking or repeated unlocking). The condition may occur more frequently in damp conditions such as driving the vehicle in the rain or taking the vehicle through a car wash. DIAGNOSIS: Vehicles that demonstrate this condition may have water weeping into the door/liftgate lock cylinder switches causing the switch to intermittently short across the internal circuit. This in turn may signal the Central Timer Module (CTM) to activate the power door locks. Because of the nature of this problem, it is extremely difficult to diagnose this condition. Therefore, customers that indicate their doors intermittently lock and unlock without having the door lock switch activated or customers that indicate they hear a repeated clicking noise coming from the door locks should have the Repair Procedure performed on their vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks Intermittently Lock/Unlock by Themselves > Page 7082 PARTS REQUIRED: NOTE: **The passenger side door lock cylinder switch has been eliminated on 2002 and 2003 Durangos and on 2003 Dakotas built after April 7, 2003 (MDH 0407XX)**. REPAIR PROCEDURE: 1. Remove the driver, passenger (if equipped), and liftgate (Durango only) door lock cylinder switches. Refer to the appropriate Service Manual Group 8Q, pages 8QA and 8Q-5 or the service information available in the MDS2 for DOOR LOCK CYLINDER SWITCH and/or LIFTGATE LOCK CYLINDER SWITCH - REMOVAL AND INSTALLATION procedures. 2. The door lock cylinder switch actuator must be positioned in its neutral position prior to installing the new switch on the lock cylinder. Rotate the actuator until the actuator is positioned as shown in the following figure (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks Intermittently Lock/Unlock by Themselves > Page 7083 3. Install the driver, passenger (if equipped), and liftgate (Durango only) door lock cylinder switches. Refer to the appropriate Service Manual Group 8Q, pages 8QA and 8Q-5 or the service information available in the MDS2 for DOOR LOCK CYLINDER SWITCH and/or LIFTGATE LOCK CYLINDER SWITCH - REMOVAL AND INSTALLATION procedures. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks Intermittently Lock/Unlock by Themselves > Page 7084 FAILURE CODE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL GRILLE AND SCREEN REMOVAL 1. Open hood. 2. Remove the wiper arms. Fig. 4 3. Remove upper plastic nuts attaching cowl grille to cowl (Fig. 4). 4. Insert a small flat blade into the slots of the plastic rivet anchors in each cowl grille corner. Lift up on the flat blade to release the rivet anchors. 5. Remove cowl weatherstrip. 6. Disconnect and plug windshield washer feed line from cowl. 7. Disconnect vacuum line from cowl. 8. Separate cowl grille from cowl. INSTALLATION 1. Position cowl grille on cowl. 2. Connect vacuum line to cowl. 3. Remove the plug and connect windshield washer feed line to cowl. 4. Install cowl weatherstrip. 5. Position rivet anchors in place and press down to engage. 6. Install upper plastic nuts attaching cowl grille to cowl. 7. Install the wiper arms. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Secondary Seal Front Door Weatherstrip: Service and Repair Front Door Secondary Seal FRONT DOOR SECONDARY SEAL REMOVAL 1. Remove the push-in fasteners attaching the secondary seal to the inner door panel. 2. Separate the secondary seal from the inner door panel. INSTALLATION 1. Position the secondary seal on the inner door panel. 2. Install the push-in fasteners attaching the secondary seal to the inner door panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Secondary Seal > Page 7095 Front Door Weatherstrip: Service and Repair Front Door Weatherstrip FRONT DOOR WEATHERSTRIP REMOVAL 1. Remove A-pillar trim. Refer to Trim Panel. 2. Remove lower cowl trim. 3. Remove door sill trim. 4. Loosen upper and lower B-pillar trim to access weatherstrip. Fig. 3 5. Pull weatherstrip from pinch flange around door opening (Fig. 3). INSTALLATION 1. Clean pinch flange 2. Position the weatherstrip on the pinch flange around door opening and press into place. 3. Press B-pillar trim into place. 4. Install lower cowl trim. 5. Install door sill trim. 6. Install A-pillar trim. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Secondary Seal > Page 7096 Front Door Weatherstrip: Service and Repair Roof Rail Weatherstrip/Retainer ROOF RAIL WEATHERSTRIP/RETAINER REMOVAL 1. Release door latch and open door. 2. The rearward corner of the weatherstrip is adhesively attached to the body. Peel back the corner of the weatherstrip to release it from the body. Fig. 9 3. Pull weatherstrip from retainer (Fig. 9). Fig. 10 4. Remove screws attaching retainer to roof rail (Fig. 10). 5. Separate retainer from vehicle. INSTALLATION NOTE: The screws attaching the retainer to the roof are coated with wax to prevent water leakage. If the retainer has been removed from the roof, replace the screws. 1. Ensure the area where tape secures the weatherstrip is clean. Use Mopar(R) Super Clean or equivalent. 2. Position retainer on vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Secondary Seal > Page 7097 3. Install screws attaching retainer to roof rail. 4. Starting at the forward end of retainer, push weatherstrip on until seated. 5. Peel the backing from the rearward end of the weatherstrip and press to secure. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Inner Belt Weatherstrip Front Door Window Glass Weatherstrip: Service and Repair Front Door Inner Belt Weatherstrip FRONT DOOR INNER BELT WEATHERSTRIP REMOVAL 1. Remove trim panel. Fig. 2 2. Peel seal from door (Fig. 2). INSTALLATION 1. Slide seal into position on door. 2. Install the trim panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Inner Belt Weatherstrip > Page 7102 Front Door Window Glass Weatherstrip: Service and Repair Front Door Outer Belt Weatherstrip FRONT DOOR OUTER BELT WEATHERSTRIP REMOVAL 1. Lower glass. Fig. 2 2. Lift rearward corner of weatherstrip and slide weatherstrip rearward (Fig. 2). INSTALLATION 1. Lightly lubricate weatherstrip with silicone and slide weatherstrip behind mirror. 2. Push weatherstrip down to seat onto door. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Inner Belt Weatherstrip > Page 7103 Front Door Window Glass Weatherstrip: Service and Repair Front Door Glass Run Weatherstrip FRONT DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove glass. Fig. 2 2. Pull the glass run weatherstrip and run channels from the window opening (Fig. 2). 3. Pull the glass run weatherstrip from the run channels. INSTALLATION 1. Install the glass run weatherstrip in the run channels. 2. Install the glass run weatherstrip in the window opening. 3. Position the run channels in the door. 4. Install glass. 5. Install door trim panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Inner Belt Weatherstrip > Page 7104 Front Door Window Glass Weatherstrip: Service and Repair Glass Run Channel GLASS RUN CHANNEL REMOVAL 1. Remove trim panel. 2. Remove water dam as necessary to access lower run channels. Fig. 5 3. Remove bolts attaching lower glass run channels to door panel (Fig. 5). 4. Remove glass. 5. Slide lower run channels downward to disengage from upper run channels. 6. Remove lower run channels from door. INSTALLATI0N 1. Position lower run channels in door. 2. Slide lower run channels upward to engage in to upper run channels. 3. Install glass. 4. Install bolts attaching lower glass run channels to door panel. 5. Install water dam. 6. Install trim panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Hood Weatherstrip > Component Information > Service and Repair > Hood Seal Hood Weatherstrip: Service and Repair Hood Seal HOOD SEAL REMOVAL Fig. 2 1. Remove push-in fasteners attaching hood seal to inner hood panel (Fig. 2). 2. Separate hood seal from vehicle. INSTALLATI0N 1. Position hood seal on inner hood panel. 2. Install push-in fasteners attaching hood seal to inner hood panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Hood Weatherstrip > Component Information > Service and Repair > Hood Seal > Page 7109 Hood Weatherstrip: Service and Repair Cowl Weatherstrip COWL WEATHERSTRIP REMOVAL Fig. 1 1. Grasp cowl seal and pull seal from flange (Fig. 1). 2. Separate cowl seal from vehicle. INSTALLATION 1. Position cowl seal on flange and press into place. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > C-Pillar Seal Rear Door Weatherstrip: Service and Repair C-Pillar Seal C-PILLAR SEAL REMOVAL-C-PILLAR SEAL NOTE: The seal is attached to the door with adhesive tape. Fig. 11 1. Peel the seal from the door (Fig. 11). INSTALLATION-C-PILLAR SEAL 1. Clean the contact area with Mopar(R) Super Kleen or equivalent. 2. Remove the carrier for the seal 3. Align the seal on the door and press into place. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > C-Pillar Seal > Page 7114 Rear Door Weatherstrip: Service and Repair Rear Door Secondary Weatherstrip REAR DOOR SECONDARY WEATHERSTRIP REMOVAL Fig. 7 1. Separate the secondary seal from the inner door panel (Fig. 7). INSTALLATION 1. Thoroughly clean the area of old adhesive. Use Mopar(R) Super Kleen or equivalent. 2. Position the secondary seal on the inner door panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > C-Pillar Seal > Page 7115 Rear Door Weatherstrip: Service and Repair Rear Door Weatherstrip REAR DOOR WEATHERSTRIP REMOVAL 1. Remove door sill trim. 2. Loosen upper and lower B-pillar trim to access weatherstrip. 3. Remove C-pillar trim. Refer to Trim Panel. 4. Pull quarter panel trim outward to access weatherstrip. Fig. 8 5. Pull weatherstrip from pinch flange around door opening (Fig. 8). INSTALLATION 1. Clean pinch flange 2. Position the weatherstrip on the pinch flange around door opening and press into place. 3. Reposition quarter panel trim. 4. Install C-pillar trim. 5. Reposition B-pillar trim. 6. Install door sill trim. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > C-Pillar Seal > Page 7116 Rear Door Weatherstrip: Service and Repair Roof Rail Weatherstrip/Retainer ROOF RAIL WEATHERSTRIP/RETAINER REMOVAL 1. Release door latch and open door. 2. The rearward corner of the weatherstrip is adhesively attached to the body. Peel back the corner of the weatherstrip to release it from the body. Fig. 9 3. Pull weatherstrip from retainer (Fig. 9). Fig. 10 4. Remove screws attaching retainer to roof rail (Fig. 10). 5. Separate retainer from vehicle. INSTALLATION NOTE: The screws attaching the retainer to the roof are coated with wax to prevent water leakage. If the retainer has been removed from the roof, replace the screws. 1. Ensure the area where tape secures the weatherstrip is clean. Use Mopar(R) Super Clean or equivalent. 2. Position retainer on vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > C-Pillar Seal > Page 7117 3. Install screws attaching retainer to roof rail. 4. Starting at the forward end of retainer, push weatherstrip on until seated. 5. Peel the backing from the rearward end of the weatherstrip and press to secure. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel Rear Door Window Glass Weatherstrip: Service and Repair Glass Run Channel GLASS RUN CHANNEL REMOVAL 1. Remove waterdam. Refer to Rear Door Panel. Fig. 4 2. Ensure glass is in full up position and supported. Remove bolts attaching the run channels to door inner panel (Fig. 4). 3. Remove speaker, if necessary. 4. Separate run channels from door. INSTALLATION 1. Position run channels in door. 2. Install bolts attaching the run channels to door inner panel (Fig. 4). 3. Install speaker, if necessary. 4. Install waterdam. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 7122 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Inner Belt Weatherstrip REAR DOOR INNER BELT WEATHERSTRIP REMOVAL 1. Remove trim panel. Fig. 6 2. Pull weatherstrip from inner door panel (Fig. 6). INSTALLATION 1. Position weatherstrip on inner door panel (Fig. 6). 2. Press into place. 3. Install trim panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 7123 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Glass Run Weatherstrip REAR DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove trim panel. 2. Remove inner belt weatherstrip. 3. Remove outer beltline weatherstrip. Fig. 5 4. Pull weatherstrip from door frame and divider bar channel (Fig. 5). INSTALLATION 1. Position weatherstrip in door frame and divider bar channel. 2. Install outer beltline weatherstrip. 3. Install inner beltline weatherstrip. 4. Install trim panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 7124 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Outer Belt Weatherstrip REAR DOOR OUTER BELT WEATHERSTRIP REMOVAL 1. Lower glass. Fig. 6 2. Lift corner of weatherstrip upward and remove weatherstrip from outer door panel (Fig. 6). INSTALLATION 1. Position weatherstrip on outer door panel (Fig. 6). 2. Press into place. 3. Raise glass. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Trunk / Liftgate Weatherstrip > Component Information > Service and Repair Trunk / Liftgate Weatherstrip: Service and Repair LIFTGATE OPENING WEATHERSTRIP REMOVAL 1. Remove liftgate opening upper trim. 2. Remove liftgate opening scuff plate. Fig. 4 3. Pull weatherstrip from liftgate opening (Fig. 4). INSTALLATION 1. Position weatherstrip in liftgate opening and align corners (Fig. 4). 2. Press weatherstrip onto flange and carefully place over quarter panel trim. 3. Connect ends at bottom/center of liftgate opening. 4. Install liftgate opening scuff plate. 5. Install liftgate opening upper trim. 6. Carefully place weatherstrip over trim using a fiber stick. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications Cruise Control Servo: Specifications Servo Mounting Bracket-to-Servo Nuts ................................................................................................................................................ 8.5 Nm (75 In. Lbs.) Servo Mounting Bracket-to-Body Nuts ..................................................................................................................................... 7 - 10 Nm (63 - 94 In. Lbs.) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 7132 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 7133 Speed Control Servo Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 7134 Cruise Control Servo: Description and Operation The servo unit consists of a solenoid valve body, and a vacuum chamber. The solenoid valve body contains three solenoids: - Vacuum - Vent - Dump The vacuum chamber contains a diaphragm with a cable attached to control the throttle linkage. The Powertrain Control Module (PCM) controls the solenoid valve body. The solenoid valve body controls the application and release of vacuum to the diaphragm of the vacuum servo. The servo unit cannot be repaired and is serviced only as a complete assembly. Power is supplied to the servo's by the PCM through the brake switch. The PCM controls the ground path for the vacuum and vent solenoids. The dump solenoid is energized anytime it receives power. If power to the dump solenoid is interrupted, the solenoid dumps vacuum in the servo. This provides a safety backup to the vent and vacuum solenoids. The vacuum and vent solenoids must be grounded at the PCM to operate. When the PCM grounds the vacuum servo solenoid, the solenoid allows vacuum to enter the servo and pull open the throttle plate using the cable. When the PCM breaks the ground, the solenoid closes and no more vacuum is allowed to enter the servo. The PCM also operates the vent solenoid via ground. The vent solenoid opens and closes a passage to bleed or hold vacuum in the servo as required. The PCM duty cycles the vacuum and vent solenoids to maintain the set speed, or to accelerate and decelerate the vehicle. To increase throttle opening, the PCM grounds the vacuum and vent solenoids. To decrease throttle opening, the PCM removes the grounds from the vacuum and vent solenoids. When the brake is released, if vehicle speed exceeds 30 mph to resume, 35 mph to set, and the RES/ACCEL switch has been depressed, ground for the vent and vacuum circuits is restored. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 7135 Cruise Control Servo: Service and Repair REMOVAL 1. Disconnect negative battery cable at battery. Fig. 5 Speed Control Servo Location 2. Disconnect vacuum hose (line) at servo. 3. Disconnect electrical connector at servo. 4. Disconnect servo cable at throttle body. Servo Cable Clip Remove/Install - Typical 5. Remove 2 mounting nuts holding servo cable sleeve to bracket or. 6. Pull speed control cable sleeve and servo away from servo mounting bracket to expose cable retaining clip and remove clip. Note: The servo mounting bracket displayed in is a typical bracket and may/may not be applicable to this model vehicle. 7. Remove servo from mounting bracket. While removing, note orientation of servo to bracket. INSTALLATION Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 7136 1. Position servo to mounting bracket. 2. Align hole in cable connector with hole in servo pin. Install cable-to-servo retaining clip. 3. Insert servo mounting studs through holes in servo mounting bracket. 4. Install servo mounting nuts and tighten to 8.5 Nm (75 in. lbs.). 5. Connect vacuum line at servo. 6. Connect electrical connector at servo. 7. Connect servo cable to throttle body. 8. Connect negative battery cable to battery. 9. Before starting engine, operate accelerator pedal to check for any binding. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Locations > Page 7140 Cruise Control Servo Cable: Description and Operation The speed control servo cable is connected between the speed control vacuum servo diaphragm and the throttle body control linkage. This cable causes the throttle control linkage to open or close the throttle valve in response to movement of the vacuum servo diaphragm. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Locations > Page 7141 Cruise Control Servo Cable: Service and Repair REMOVAL 1. Disconnect negative battery cable at battery. 2. Remove air box housing from throttle body. The accelerator cable must be partially removed to gain access to speed control cable. Cable Connectors at Bell Crank 3. Using finger pressure only, disconnect accelerator cable connector at throttle body bellcrank pin by pushing connector off bellcrank pin towards front of vehicle. DO NOT try to pull connector off perpendicular to the bellcrank pin. Connector Will be broken. 4. Lift accelerator cable from top of cable cam. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Locations > Page 7142 Fig. 2 Accelerator Cable Release Tab 5. Press tab to release plastic cable mount from bracket. Press on tab only enough to release cable from bracket. If tab is pressed too much, it will be broken. Slide plastic mount towards passenger side of vehicle to remove cable from bracket. 6. Using finger pressure only, disconnect speed control cable connector at throttle body bellcrank pin by pushing connector off bellcrank pin towards front of vehicle. DO NOT try to pull connector off perpendicular to the bellcrank pin. Connector will be broken. Speed Control Cable at Bracket Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Locations > Page 7143 7. Slide speed control cable plastic mount towards passenger side of vehicle to remove cable from bracket. 8. Remove servo cable from servo. Refer to Speed Control Servo Removal/installation. INSTALLATION 1. Install end of cable to speed control servo. Refer to Speed Control Servo Removal/installation. 2. Slide speed control cable plastic mount into bracket. 3. Install speed control cable connector onto throttle body bellcrank pin (snaps on). 4. Slide accelerator cable plastic mount into bracket. Continue sliding until tab is aligned to hole in mounting bracket. 5. Route accelerator cable over top of cable cam. 6. Install accelerator cable connector onto throttle body bellcrank pin (snaps on). 7. Install air box housing to throttle body. 8. Connect negative battery cable at battery. 9. Before starting engine, operate accelerator pedal to check for any binding. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Specifications Cruise Control Switch: Specifications Switch Module Mounting Screws ........................................................................................................................................................... 1.5 Nm (14 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 7147 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 7148 Cruise Control Switch: Diagrams Left Speed Control Switch Right Speed Control Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 7149 Cruise Control Switch: Service Precautions WARNING: BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION, REMOVE AND ISOLATE THE NEGATIVE (-) CABLE FROM THE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. THEN WAIT TWO MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 7150 Cruise Control Switch: Description and Operation There are two separate switch pods that operate the speed control system. The steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM for ON, OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. Refer to the owner's manual for more information on speed control switch functions and setting procedures. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. When speed control is selected by depressing the ON, OFF switch, the PCM allows a set speed to be stored in its RAM for speed control. To store a set speed, depress the SET switch while the vehicle is moving at a speed between approximately 35 and 85 mph. In order for the speed control to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral. The speed control can be disengaged manually by: - Stepping on the brake pedal - Depressing the OFF switch - Depressing the CANCEL switch. The speed control can be disengaged also by any of the following conditions: - An indication of Park or Neutral - The VSS signal increases at a rate of 10 mph per second (indicates that the co-efficient of friction between the road surface and tires is extremely low) - Depressing the clutch pedal. - Excessive engine rpm (indicates that the transmission may be in a low gear) - The VSS signal decreases at a rate of 10 mph per second (indicates that the vehicle may have decelerated at an extremely high rate) - If the actual speed is not within 20 mph of the set speed The previous disengagement conditions are programmed for added safety. Once the speed control has been disengaged, depressing the ACCEL switch restores the vehicle to the target speed that was stored in the PCM's RAM. NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's RAM. If, while the speed control is engaged, the driver wishes to increase vehicle speed, the PCM is programmed for an acceleration feature. With the ACCEL switch held closed, the vehicle accelerates slowly to the desired speed. The new target speed is stored in the PCM's RAM when the ACCEL switch is released. The PCM also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph for each momentary switch activation of the ACCEL switch. The PCM also provides a means to decelerate without disengaging speed control. To decelerate from an existing recorded target speed, depress and hold the COAST switch until the desired speed is reached. Then release the switch. The ON, OFF switch operates two components: the PCM's ON, OFF input, and the battery voltage to the brake switch, which powers the speed control servo. Multiplexing The PCM sends out 5 volts through a fixed resistor and monitors the voltage change between the fixed resistor and the switches. If none of the switches are depressed, the PCM will measure 5 volts at the sensor point (open circuit). If a switch with no resistor is closed, the PCM will measure 0 volts (grounded circuit). Now, if a resistor is added to a switch, then the PCM will measure some voltage proportional to the size of the resistor. By adding a different resistor to each switch, the PCM will see a different voltage depending on which switch is pushed. Another resistor has been added to the 'at rest circuit' causing the PCM to never see 5 volts. This was done for diagnostic purposes. If the switch circuit should open (bad connection), then the PCM will see the 5 volts and know the circuit is bad. The PCM will then set an open circuit fault. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 7151 Cruise Control Switch: Service and Repair REMOVAL WARNING: BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION, REMOVE AND ISOLATE THE NEGATIVE (-) CABLE FROM THE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. THEN WAIT TWO MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE INJURY. 1. Disconnect and isolate negative battery cable. 2. Remove airbag module. Refer to Passive Restraint Systems for procedures. Speed Control Switches 3. Remove switch-to-steering wheel mounting screws. 4. Remove switch. 5. Remove electrical connector at switch. INSTALLATION 1. Install electrical connector to switch. 2. Install switch and mounting screws. 3. Tighten screws to 1.5 Nm (14 in. lbs.) torque. 4. Install airbag module. Refer to Passive Restraint Systems for procedures. 5. Connect negative battery cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Hose > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Specifications Cruise Control Vacuum Reservoir: Specifications Vacuum Reservoir Mounting Bolt (screws) .......................................................................................................................................... 2.2 Nm (20 In. Lbs.) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Specifications > Page 7158 Cruise Control Vacuum Reservoir: Locations Fig. 8 Vacuum Reservoir Mounting Cowl Plenum Cover/Grille Panel Remove/Install The vacuum reservoir is located under the plastic cowl plenum cover at lower base of windshield or. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Specifications > Page 7159 Cruise Control Vacuum Reservoir: Description and Operation The vacuum reservoir is a plastic storage tank connected to an engine vacuum source by vacuum lines. The vacuum reservoir is used to supply the vacuum needed to maintain proper speed control operation when engine vacuum drops, such as in climbing a grade while driving. A one-way check valve is used in the vacuum line between the reservoir and the vacuum source. This check valve is used to trap engine vacuum in the reservoir. On certain vehicle applications, this reservoir is shared with the heating/air-conditioning system. The vacuum reservoir cannot be repaired and must be replaced if faulty. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Specifications > Page 7160 Cruise Control Vacuum Reservoir: Testing and Inspection Vacuum Supply Test 1. Disconnect vacuum hose at speed control servo and install a vacuum gauge into the disconnected hose. 2. Start engine and observe gauge at idle. Vacuum gauge should read at least ten inches of mercury. 3. If vacuum is less than ten inches of mercury, determine source of leak. Check vacuum line to engine for leaks. Also check actual engine intake manifold vacuum. If manifold vacuum does not meet this requirement, check for poor engine performance and repair as necessary. 4. If vacuum line to engine is not leaking, check for leak at vacuum reservoir. To locate and gain access to reservoir, refer to Vacuum Reservoir Removal/Installation. Disconnect vacuum line at reservoir and connect a hand-operated vacuum pump to reservoir fitting. Apply vacuum. Reservoir vacuum should not bleed OFF. If vacuum is being lost, replace reservoir. 5. Verify operation of one-way check valve and check it for leaks. a. Locate one-way check valve. The valve is located in vacuum line between vacuum reservoir and engine vacuum source. Disconnect vacuum hoses (lines) at each end of valve. b. Connect a hand-operated vacuum pump to reservoir end of check valve. Apply vacuum. Vacuum should not bleed OFF. If vacuum is being lost, replace one-way check valve. c. Connect a hand-operated vacuum pump to vacuum source end of check valve. Apply vacuum. Vacuum should flow through valve. If vacuum is not flowing, replace one-way check valve. Seal the fitting at opposite end of valve with a finger and apply vacuum. If vacuum will not hold, diaphragm within check valve has ruptured. Replace valve. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Specifications > Page 7161 Cruise Control Vacuum Reservoir: Service and Repair REMOVAL Fig. 8 Vacuum Reservoir Mounting Cowl Plenum Cover/Grille Panel Remove/Install The vacuum reservoir is located under the plastic cowl plenum cover at lower base of windshield or. 1. Disconnect and isolate negative battery at cable. 2. Remove both windshield wiper arm/blade assemblies. Refer to Wiper and Washer Systems. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Specifications > Page 7162 Cowl Grille Panel Weather-strip 3. Remove rubber weather-strip at front edge of cowl grill. 4. Remove four plastic nuts securing cowl plenum cover/grille panel to studs on cowl top panel near base of windshield. 5. Remove two plastic rivets securing each side of the cowl plenum cover/grille panel to cowl plenum panel and cowl top panel. 6. Lift cowl plenum cover/grille panel from vehicle far enough to access windshield washer and vacuum plumbing near right end of cowl plenum. 7. Disconnect windshield washer supply hose at in-line connector. 8. Disconnect vacuum supply hose from vacuum supply connector at vacuum reservoir. 9. Remove cowl plenum cover/grille panel from vehicle. 10. Remove three reservoir mounting screws. 11. Remove vacuum reservoir from vehicle. INSTALLATION The vacuum reservoir is located under the plastic cowl plenum cover at lower base of windshield or. 1. Install vacuum reservoir and three mounting screws to plastic cowl cover. Tighten three screws to 2.2 Nm (20 in. lbs.) torque. 2. Position cowl plenum cover/grille panel to vehicle. 3. Connect vacuum supply hose to vacuum reservoir. 4. Connect windshield washer supply hose at inline connector. 5. Install and tighten cowl cover fasteners to vehicle body. 6. Install rubber weather-strip at front edge of cowl grill. 7. Install windshield wiper arms. Refer to Wiper and Washer Systems. 8. Connect negative battery to cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications Cruise Control Switch: Specifications Switch Module Mounting Screws ........................................................................................................................................................... 1.5 Nm (14 In. Lbs) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 7167 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 7168 Cruise Control Switch: Diagrams Left Speed Control Switch Right Speed Control Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 7169 Cruise Control Switch: Service Precautions WARNING: BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION, REMOVE AND ISOLATE THE NEGATIVE (-) CABLE FROM THE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. THEN WAIT TWO MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 7170 Cruise Control Switch: Description and Operation There are two separate switch pods that operate the speed control system. The steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM for ON, OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. Refer to the owner's manual for more information on speed control switch functions and setting procedures. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. When speed control is selected by depressing the ON, OFF switch, the PCM allows a set speed to be stored in its RAM for speed control. To store a set speed, depress the SET switch while the vehicle is moving at a speed between approximately 35 and 85 mph. In order for the speed control to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral. The speed control can be disengaged manually by: - Stepping on the brake pedal - Depressing the OFF switch - Depressing the CANCEL switch. The speed control can be disengaged also by any of the following conditions: - An indication of Park or Neutral - The VSS signal increases at a rate of 10 mph per second (indicates that the co-efficient of friction between the road surface and tires is extremely low) - Depressing the clutch pedal. - Excessive engine rpm (indicates that the transmission may be in a low gear) - The VSS signal decreases at a rate of 10 mph per second (indicates that the vehicle may have decelerated at an extremely high rate) - If the actual speed is not within 20 mph of the set speed The previous disengagement conditions are programmed for added safety. Once the speed control has been disengaged, depressing the ACCEL switch restores the vehicle to the target speed that was stored in the PCM's RAM. NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's RAM. If, while the speed control is engaged, the driver wishes to increase vehicle speed, the PCM is programmed for an acceleration feature. With the ACCEL switch held closed, the vehicle accelerates slowly to the desired speed. The new target speed is stored in the PCM's RAM when the ACCEL switch is released. The PCM also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph for each momentary switch activation of the ACCEL switch. The PCM also provides a means to decelerate without disengaging speed control. To decelerate from an existing recorded target speed, depress and hold the COAST switch until the desired speed is reached. Then release the switch. The ON, OFF switch operates two components: the PCM's ON, OFF input, and the battery voltage to the brake switch, which powers the speed control servo. Multiplexing The PCM sends out 5 volts through a fixed resistor and monitors the voltage change between the fixed resistor and the switches. If none of the switches are depressed, the PCM will measure 5 volts at the sensor point (open circuit). If a switch with no resistor is closed, the PCM will measure 0 volts (grounded circuit). Now, if a resistor is added to a switch, then the PCM will measure some voltage proportional to the size of the resistor. By adding a different resistor to each switch, the PCM will see a different voltage depending on which switch is pushed. Another resistor has been added to the 'at rest circuit' causing the PCM to never see 5 volts. This was done for diagnostic purposes. If the switch circuit should open (bad connection), then the PCM will see the 5 volts and know the circuit is bad. The PCM will then set an open circuit fault. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 7171 Cruise Control Switch: Service and Repair REMOVAL WARNING: BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION, REMOVE AND ISOLATE THE NEGATIVE (-) CABLE FROM THE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. THEN WAIT TWO MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE INJURY. 1. Disconnect and isolate negative battery cable. 2. Remove airbag module. Refer to Passive Restraint Systems for procedures. Speed Control Switches 3. Remove switch-to-steering wheel mounting screws. 4. Remove switch. 5. Remove electrical connector at switch. INSTALLATION 1. Install electrical connector to switch. 2. Install switch and mounting screws. 3. Tighten screws to 1.5 Nm (14 in. lbs.) torque. 4. Install airbag module. Refer to Passive Restraint Systems for procedures. 5. Connect negative battery cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Locations ABS Light: Locations The ABS indicator is located in the Information Center area of the instrument cluster, to the left of center. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Locations > Page 7176 ABS Light: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Anti-lock Brake .................................................................................................................................... .............................................................. PC194 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Locations > Page 7177 ABS Light: Description and Operation An Antilock Brake System (ABS) indicator is standard equipment on all instrument clusters. This indicator serves both the standard equipment Rear Wheel Anti-Lock (RWAL) and optional equipment 4-Wheel Anti-Lock (4WAL) brake systems. The ABS indicator is located in the Information Center area of the instrument cluster, to the left of center. The ABS indicator consists of a stencilled cutout of the International Control and Display Symbol icon for "Failure of Anti-lock Braking System" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber lens behind the cutout in the opaque layer of the overlay causes the icon to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by a Light Emitting Diode (LED) soldered onto the instrument cluster electronic circuit board. The ABS indicator is serviced as a unit with the instrument cluster. The ABS indicator gives an indication to the vehicle operator when the ABS system is faulty or inoperative. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Controller Antilock Brake (CAB) over the Programmable Communications Interface (PCI) data bus. The ABS indicator Light Emitting Diode (LED) receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions; therefore, the LED will always be OFF when the ignition switch is in any position except ON or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the ABS indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the ABS indicator is illuminated by the cluster for about two seconds as a bulb test. - ABS Lamp-ON Message - Each time the cluster receives a lamp-ON message from the CAB, the ABS indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the CAB, or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no lamp-ON or lamp-OFF messages from the CAB for six consecutive seconds, the ABS indicator is illuminated. The indicator remains illuminated until the cluster receives a valid message from the CAB, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the instrument cluster is put through the actuator test, the ABS indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. - ABS Diagnostic Test - The ABS indicator is blinked ON and OFF by lamp-ON and lamp-OFF messages from the CAB during the performance of the ABS diagnostic tests. The CAB continually monitors the ABS circuits and sensors to decide whether the system is in good operating condition. The CAB then sends the proper lamp-ON or lamp-OFF messages to the instrument cluster. If the CAB sends a lamp-ON message after the bulb test, it indicates that the CAB has detected a system malfunction and/or that the ABS system has become inoperative. The CAB will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the ABS indicator fails to light due to an open or short in the cluster ABS indicator circuit, the cluster sends a message notifying the CAB of the condition, and the CAB will store a DTC. For proper diagnosis of the antilock brake system, the CAB, the PCI data bus, or the message inputs to the instrument cluster that control the ABS indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7182 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7183 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7184 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7185 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7186 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7187 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7188 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7189 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7190 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7191 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7192 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7193 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7194 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7195 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7196 Audible Warning Device: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7197 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7198 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7199 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7200 Chime Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 7201 Audible Warning Device: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 7202 Audible Warning Device: Description and Operation For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. See: Body and Frame/Body Control Systems/Central Timer Module CHIME WARNING SYSTEM A chime warning system is standard factory-installed equipment on this model. The chime warning system uses a single chime tone generator that is integral to the Central Timer Module (CTM) to provide an audible indication of various vehicle conditions that may require the attention of the vehicle operator. The chime warning system includes the following major components, which are described in further detail elsewhere: - Central Timer Module - The Central Timer Module (CTM) is located on the cowl side inner panel, below the driver side end of the instrument panel. The CTM contains an integral chime tone generator, integrated circuitry, a central processing unit, and the programming to provide all of the proper chime warning system features based upon the monitored inputs. The CTM circuitry monitors hard wired switch inputs as well as electronic messages received from other electronic modules in the vehicle over the Programmable Communications Interface (PCI) data bus network. - Door Ajar Switch - Door ajar switches are integral to each door latch. These switches provide inputs to the chime warning system indicating whether a door is opened or closed. - Headlamp Switch - The headlamp switch is located on the instrument panel outboard of the steering column. The headlamp switch provides input to the chime warning system indicating whether any interior or exterior lighting is turned ON or OFF. - Ignition Switch - A key-in ignition switch is integral to the ignition switch. The key-in ignition switch provides an input to the chime warning system indicating whether a key is present in the ignition lock cylinder. Hard wired circuitry connects many of the chime warning system components to each other through the electrical system of the vehicle. These hard wired circuits are integral to several wire harnesses, which are routed throughout the vehicle and retained by many different methods. These circuits may be connected to each other, to the vehicle electrical system and to the chime warning system components through the use of a combination of soldered splices, splice block connectors, and many different types of wire harness terminal connectors and insulators. The CTM chime warning system circuitry and the integral chime tone generator cannot be adjusted or repaired. If the CTM or the chime tone generator are damaged or faulty, the CTM unit must be replaced. The chime warning system is designed to provide an audible output as an indication of various conditions that may require the attention or awareness of the vehicle operator. The chime warning system components operate on battery current received through a fused B(+) fuse in the Junction Block (JB) on a non-switched fused B(+) circuit so that the system may operate regardless of the ignition switch position. The chime warning system provides an audible indication to the vehicle operator under the following conditions: - Compass Mini-Trip Computer (CMTC) Reset - The Central Timer Module (CTM) chime tone generator will generate one chime tone each time a Programmable Communications Interface (PCI) data bus message is received from the optional CMTC indicating that the CMTC data has been reset. - Door Ajar Warning - The CTM chime tone generator will generate repetitive chime tones at a slow rate to announce that a hard wired input from any door ajar switch indicates that a door is open with the ignition switch in the ON position. The chimes will continue to sound until the all doors are closed or the ignition switch is turned to the OFF position, whichever occurs first. - Fasten Seat Belt Warning - The CTM chime tone generator will generate repetitive chime tones at a slow rate to announce that a hard wired input from the seat belt switch to the Electro-Mechanical Instrument Cluster (EMIC) indicates that the driver side front seat belt is not fastened with the ignition switch in the ON position. Unless the driver side front seat belt is fastened the chimes will continue to sound for a duration of about seven seconds each time the ignition switch is turned to the ON position, or until the driver side front seat belt is fastened, whichever occurs first. This chime tone is based upon a PCI data bus chime request message input to the CTM from the EMIC, but is not tied to the operation of the EMIC "Seatbelt" indicator. - Head/Park/Courtesy Lights-On Warning - The CTM chime tone generator will generate repetitive chime ones at a fast rate to announce that hard wired inputs from the driver door ajar switch, headlamp switch, and ignition switch indicate that the exterior or courtesy lamps are turned ON with the driver side front door opened and the ignition switch in the OFF position. The chimes will continue to sound until the exterior or courtesy lamps are turned OFF, the driver side front door is closed, or the ignition switch is turned to the ON position, whichever occurs first. - Key-In-Ignition Warning - The CTM chime tone generator will generate repetitive chime tones at a fast rate to announce that hard wired inputs from the driver door ajar switch, headlamp switch, and ignition switch indicate that the key is in the ignition lock cylinder with the driver side front door opened and the ignition switch in the OFF position. The chimes will continue to sound until the key is removed from the ignition lock cylinder, the driver side front door is closed, or the ignition switch is turned to the ON position, whichever occurs first. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 7203 - Overspeed Warning - The CTM chime tone generator will generate repetitive chime tones at a slow rate to announce that a PCI data bus vehicle speed message from the Powertrain Control Module (PCM) indicates that the vehicle speed is over a programmed speed value. This feature is only enabled on a CTM that has been programmed with a Middle East Gulf Coast Country (GCC) country code. - Warning Chime Support - The CTM chime tone generator will generate repetitive chime tones at a slow rate to announce that a PCI data bus chime request message input has been received from the EMIC or the Airbag Control Module (ACM). These chime tones provide an audible alert to the vehicle operator that supplements certain visual indications displayed by the EMIC. Supplemented indications include the following: - The "Airbag" indicator is illuminated. The ACM sends a chime request to the CTM at the same time it sends an airbag lamp-ON request to the EMIC. The chimes will continue to sound for a duration of about four seconds each time the indicator is illuminated or until the ignition switch is turned to the OFF position, whichever occurs first. - The "Check Gages" indicator is illuminated. The EMIC sends a chime request to the CTM. The chimes will continue to sound for a duration of about two seconds each time the indicator is illuminated or until the ignition switch is turned to the OFF position, whichever occurs first. - The "Low Fuel" indicator is illuminated. The EMIC sends a chime request to the CTM. The chimes will continue to sound for a duration of about two seconds each time the indicator is illuminated or until the ignition switch is turned to the OFF position, whichever occurs first. - The "Low Wash" indicator is illuminated. The EMIC sends a chime request to the CTM. The chimes will continue to sound for a duration of about two seconds each time the indicator is illuminated or until the ignition switch is turned to the OFF position, whichever occurs first. - The "Trans Temp" indicator is illuminated (automatic transmission only). The EMIC sends a chime request to the CTM. The chimes will continue to sound for a duration of about two seconds each time the indicator is illuminated or until the ignition switch is turned to the OFF position, whichever occurs first. - A turn signal indicator is illuminated after the vehicle has surpassed a programmed speed and distance. The EMIC sends a chime request to the CTM. The chimes will continue to sound until the turn signal is turned OFF, or until the vehicle speed is reduced below the programmed level, whichever occurs first. The CTM provides chime service for all available features in the chime warning system. The CTM relies upon its internal programming and hard wired inputs from the door ajar switches, the headlamp switch, and the key-in ignition switch (ignition switch) to provide chime service for the head/park/courtesy lights-on reminder, the key-in ignition reminder, and the door ajar warning. The CTM relies upon electronic message inputs received from other electronic modules over the PCI data bus network to provide chime service for all of the remaining chime warning system features. Upon receiving the proper inputs, the CTM activates the integral chime tone generator to provide the audible chime tone to the vehicle operator. The chime tone generator in the CTM is capable of producing a single short beep and repeated chime tones at two different rates, slow and fast. The slow chime rate is about 50 chime tones per minute, while the fast chime rate is about 180 chime tones per minute. The slow chime rate, 50 chimes per minute, is for reminders while the fast chime rate, 180 chimes per minute, is for serious conditions that require immediate attention. The high rate chime sounds when the key is left in the ignition and the driver's door is open or if the headlights or the courtesy lights are left on. The low rate chime sounds for any of the other conditions. There is a variable rate feature that allows the chime to sound continuously for key-in and headlamp warning as long as the door is open. The seat belt warning chime is activated for six seconds, and all other chime conditions will activate the chime once at the same time the warning light on the cluster is illuminated. The Chime will sound for the following conditions: Ignition OFF key in ignition, driver's door open - Ignition OFF, headlamps ON, driver's door open - Ignition OFF, courtesy lamps ON, driver's door open - Seat belt warning (after prove-out) - Malfunction Indicator lamp (MIL) illuminated (after prove-out) - Airbag lamp illuminated (after prove-out) - Check gauges lamp - Low fuel warning - Low washer fluid lamp - Door ajar warning - Transmission temperature lamp - Turn signal on reminder warning - Button pushed on compass mini-trip computer The hard wired chime warning system inputs to the CTM, as well as other hard wired circuits for this system may be diagnosed and tested using conventional diagnostic tools and procedures. See the owner's manual in the vehicle glove box for more information on the features provided by the chime warning system. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 7204 Audible Warning Device: Testing and Inspection For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. See: Body and Frame/Body Control Systems/Central Timer Module Chime Warning System Diagnosis (Part 1 of 3) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 7205 Chime Warning System Diagnosis (Part 2 Of 3) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 7206 Chime Warning System Diagnosis (Part 3 Of 3) The hard wired chime warning system inputs to the Central Timer Module (CTM), as well as other hard wired circuits for this system may be diagnosed and tested using conventional diagnostic tools and procedures. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 7207 Audible Warning Device: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: Before replacing a Central Timer Module (CTM), use a DRB III scan tool to retrieve the current settings for the CTM programmable features. Refer to the appropriate diagnostic information. These settings should be duplicated in the replacement CTM using the DRB III scan tool before returning the vehicle to service. 1. Disconnect and isolate the battery negative cable. 2. Remove the trim from the left cowl side inner panel. Fig. 2 Central Timer Module 3. Disconnect the two instrument panel wire harness connectors and one body wire harness connector from the CTM connector receptacles (Fig. 2). 4. Remove the three screws that secure the CTM to the left cowl side inner panel. 5. Remove the CTM from the left cowl side inner panel. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: Before replacing a Central Timer Module (CTM), use a DRB III scan tool to retrieve the current settings for the CTM programmable features. Refer to the appropriate diagnostic information. These settings should be duplicated in the replacement high-line/premium CTM using the DRB III scan tool before returning the vehicle to service. 1. Position the CTM onto the left cowl side inner panel (Fig. 2). 2. Install and tighten the three screws that secure the CTM to the left cowl side inner panel. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the two instrument panel wire harness connectors and one body wire harness connector to the CTM connector receptacles. 4. Reinstall the trim onto the left cowl side inner panel. 5. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Locations Audible Warning Device Control Module: Locations The Central Timer Module is located behind the left side kick panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device Control Module: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7213 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7214 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7215 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7216 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7217 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7218 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7219 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7220 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7221 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7222 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7223 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7224 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7225 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7226 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7227 Audible Warning Device Control Module: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7228 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7229 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7230 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7231 Audible Warning Device Control Module: Connector Views Central Timer Module C1 Central Timer Module C2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7232 Central Timer Module C3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7233 Audible Warning Device Control Module: Electrical Diagrams 8w-45-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7234 8w-45-3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7235 8w-45-4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7236 8w-45-5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7237 8w-45-6 (Base) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7238 8w-45-7 (Light Package) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7239 8w-45-8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7240 8w-45-9 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7241 8w-45-10 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7242 8w-45-11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7243 8w-45-12 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7244 8w-45-13 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7245 8w-45-14 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7246 8w-45-15 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams See: Diagrams/Electrical Diagrams Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Page 7247 Audible Warning Device Control Module: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Page 7248 Audible Warning Device Control Module: Description and Operation For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. See: Body and Frame/Body Control Systems/Central Timer Module CENTRAL TIMER MODULE The Durango (DN) utilizes a Central Timer Module (CTM). This system is available in a Base or Highline configuration. The CTM performs most of the typical functions a Body Control Module would perform. The Base and Highline CTM provides the following features: Battery Saver Functions For Exterior and Interior Lamps - Cargo Lamps - Chime Warning - Courtesy Lamps - Dome Lamps - Dome Defeat - Door Ajar Switch Status - Fog Lamps - Head Lamp Time Delay - Intermittent Wiper Controls - Low and High Beam Head Lamps - Optical Horn - Park Lamps Additional features of Highline CTM Central Locking (VTSS) - Door Lock Inhibit - Driver Door Unlock - Enhanced Accident Response - Power Door Locks - Remote Radio - Remote Keyless Entry - Vehicle Theft Alarm (VTSS) Fig. 1 Central Timer Module The Central Timer Module is located behind the left side kick panel. It contains 26-way, 16-way and 12-way connectors. The high-line Central Timer Module (CTM) can also control some features of the audio system when the vehicle is equipped with the optional RAZ radio receiver and remote radio switches. A high-line CTM is used on high-line versions of this vehicle. The CTM combines the functions of a chime/buzzer module, an intermittent wipe module, an illuminated entry module, a remote keyless entry module, and a vehicle theft security Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Page 7249 system module in a single unit. The high-line CTM also controls and integrates many of the additional electronic functions and features included on models with this option. The RAZ radio receiver with a remote radio switch option is one of the features that the CTM controls. The CTM is programmed to send switch status messages over the J185O data bus to control the volume, seek, and pre-set station advance functions of the RAZ radio receiver. The CTM monitors the status of the remote radio switches located on the steering wheel through a hard wired circuit. The CTM then sends the proper switch status messages to the radio receiver. The electronic circuitry within the radio receiver responds to the switch status messages it receives by adjusting the radio settings as requested. In addition, radio receivers connected to the J1850 data bus have several audio system functions that can be diagnosed using a DRB scan tool. Refer to the proper Diagnostic Procedures for more information on DRB testing of the audio systems. Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. Whichever version of the CTM the vehicle is equipped with, it is concealed behind the trim on the left cowl side inner panel below the instrument panel, where it is secured with three screws. The CTM is enclosed in a molded plastic housing with three integral external connector receptacles that connect it to the vehicle electrical system through one take out and connector of the body wire harness, and two take outs and connectors of the instrument panel wire harness. The base version of the CTM is used on base models of this vehicle. These base models are not equipped with the optional power lock system, the Remote Keyless Entry (RKE) system, the rear wiper system, the Vehicle Theft Security System (VTSS), or the remote radio controls. The high-line version of the CTM is used on high-line vehicles that are equipped with one or more of those options not found on base models. The CTM utilizes integrated circuitry and information carried on the Programmable Communications Interface (PCI) data bus network along with many hard wired inputs to monitor many sensor and switch inputs throughout the vehicle. In response to those inputs, the internal circuitry and programming of the CTM allow it to supply the vehicle occupants with audible and visual information, and to control and integrate many electronic functions and features of the vehicle through both hard wired outputs and the transmission of electronic message outputs to other electronic modules in the vehicle over the PCI data bus. The features that the CTM supports or controls include the following: Automatic Door Lock - The high-line CTM provides an automatic door lock feature (also known as rolling door locks). This is a programmable feature. - Battery Protection - The CTM provides a battery saver feature that performs timed load shedding whenever courtesy, reading, visor vanity, center console, glove box, or any exterior lamps are left on with the ignition switch in the OFF position. - Central Locking - The high-line CTM on vehicles equipped with the optional Vehicle Theft Security System (VTSS) includes a central locking/ unlocking feature. - Chimes - All versions of the CTM provide chime service and beep request service through an integral chime tone generator. - Door Lock Inhibit - The high-line CTM provides a power door lock inhibit feature. - Enhanced Accident Response - The high-line CTM provides an optional enhanced accident response feature. This is a programmable feature. - Exterior Light Features - The CTM provides control of park lamps, fog lamps, and headlamps. This includes support for optical horn (also known as flash-to-pass), headlamp time delay, daytime running lamps (DRL - Canada only), and battery saver features. - Interior Light Features - The CTM provides control of courtesy lamps, dome lamps, and the liftgate lamp. This includes support for a timed illuminated entry with fade-to-OFF, interior lighting delay, courtesy illumination defeat, and battery saver features. - Intermittent Wipe Control - The CTM provides control of the intermittent wipe delay, and wipe-after-wash features for the front wiper and washer system. The high-line CTM also provides these same features for the optional rear wiper and washer system. - Panic Mode - The high-line CTM provides support for the optional RKE system panic mode including horn chirp, headlamp flash, and park lamp flash features. - Power Lock Control - The high-line CTM provides the optional power lock system features, including support for the automatic door lock and door lock inhibit modes. - Programmable Features - The CTM provides support for certain programmable features. - Remote Keyless Entry - The high-line CTM provides the optional Remote Keyless Entry (RKE) system features, including support for the RKE Lock (with optional horn chirp and park lamps flash), Unlock (with optional park lamps flash, driver-door- only unlock, and unlock-all-doors), Panic, and illuminated entry modes, as well as the ability to be programmed to recognize up to four RKE transmitters. The RKE horn chirp, park lamps flash, driver- door-only unlock, and unlock-all-doors features are programmable. - Remote Radio Switch Interface - The high- line CTM monitors and transmits the status of the optional remote radio switches on the steering wheel. - Speed Sensitive Intermittent Wipe Control - The CTM provides a speed sensitive front intermittent wipe feature. - Vehicle Theft Security System - The high-line CTM provides control of the optional Vehicle Theft Security System (VTSS) features, including support for the central locking/unlocking mode and control of the Security indicator in the instrument cluster. Hard wired circuitry connects the CTM to the electrical system of the vehicle. These hard wired circuits are integral to several wire harnesses, which are routed throughout the vehicle and retained by many different methods. These circuits may be connected to each other, to the vehicle electrical system and to the CTM through the use of a combination of soldered splices, splice block connectors, and many different types of wire harness terminal connectors and insulators. All versions of the CTM for this model are serviced only as a complete unit. Many of the electronic features in the vehicle controlled or supported by the CTM are programmable using the DRB III scan tool. In addition, the CTM software is Flash compatible, which means it can be reprogrammed using Flash reprogramming procedures. However, if any of the CTM hardware components are damaged or faulty, the entire CTM unit must be replaced. The hard wired inputs or outputs of all CTM versions can be diagnosed using conventional diagnostic tools and methods; however, for diagnosis of the CTM or the PCI data bus, the use of a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Page 7250 The microprocessor-based Central Timer Module (CTM) monitors many hard wired switch and sensor inputs as well as those resources it shares with other electronic modules in the vehicle through its communication over the Programmable Communications Interface (PCI) data bus network. The internal programming and all of these inputs allow the CTM microprocessor to determine the tasks it needs to perform and their priorities, as well as both the standard and optional features that it should provide. The CTM programming then performs those tasks and provides those features through both PCI data bus communication with other electronic modules and through hard wired outputs through a number of driver circuits, relays, and actuators. These outputs allow the CTM the ability to control numerous accessory systems in the vehicle. The CTM operates on battery current received through two fuses in the Junction Block (JB) on two non-switched fused B(+) circuits, a fused ignition switch output (run-start) circuit, and a fused ignition switch output (run-acc) circuit. This arrangement allows the CTM to provide some features regardless of the ignition switch position, while other features will operate only with the ignition switch in the Accessory, ON, and/or Start positions. The CTM receives ground through its connector and take out of the instrument panel wire harness on three separate ground circuits. Two of these circuits are grounded through a take out of the instrument panel wire harness with an eyelet terminal connector that is secured by a nut to a ground stud on the left inner cowl side panel near the CTM, while the third circuit is grounded through a take out of the instrument panel wire harness with an eyelet terminal connector that is secured by a ground screw to the left side of the floor panel transmission tunnel near the Airbag Control Module (ACM). The CTM monitors its own internal circuitry as well as many of its input and output circuits, and will store a Diagnostic Trouble Code (DTC) in electronic memory for any failure it detects. These DTCs can be retrieved and diagnosed using a DRB III scan tool. Refer to the appropriate diagnostic information. Hard Wired Inputs The hard wired inputs to the CTM include the following: Courtesy lamp switch sense - Cylinder lock switch sense - high line with VTSS only - Driver door ajar switch sense - Driver door switch mux - high line with power locks only - Fog lamp switch sense - Front washer pump/motor control - Front wiper park switch sense - Fused B(+) (two circuits) - Fused ignition switch output (run-acc) - Fused ignition switch output (run-start) - Ground (three circuits) - Headlamp switch off sense - High beam switch output - Interior lamp defeat - Intermittent front wiper mode sense - Intermittent front wiper switch signal - Key-in ignition switch sense - Liftgate ajar switch sense - Low beam switch output - Park brake switch sense - Park lamp switch sense - Passenger door ajar switch sense - Passenger door switch mux - high line with power locks only - PCI bus circuit - Radio control mux - high-line with remote radio switches only - Washer switch sense - Wiper park switch sense - Wiper switch mode sense - Wiper switch mode signal Hard Wired Outputs The hard wired outputs of the CTM include the following: Courtesy lamp driver - Door lock relay output - high-line with power locks only - Door unlock relay output - high-line with power locks only - Driver door unlock relay output - high-line with power locks only - Fog lamp relay control - with fog lamps only - Front washer pump/motor control - Front wiper park switch sense - Front wiper relay control - Glove box lamp driver - High beam indicator driver - Horn relay control - high-line with power locks only Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Page 7251 - Interior lamp driver - Left high beam driver - Left low beam driver - Park lamp relay control - Rear wiper park switch sense - high line with rear wiper and washer system only - Rear wiper relay control - high line with rear wiper and washer system only - Right high beam driver - Right low beam driver - VTSS indicator driver - high-line with VTSS only Messaging The CTM uses the following messages received from other electronic modules over the PCI data bus: Airbag Deploy (ACM) - Beep request (CMTC) - Charging System Failure (PCM) - Chime request (EMIC) - Engine RPM (PCM) - OK to Arm VTSS (PCM) - Rear Washer Status (Heater-A/C Control) - Rear Wiper Status (Heater-A/C Control) - Security indicator request (SKIM) - System Voltage (PCM) - Valid/Invalid Key (SKIM) - Vehicle Distance (PCM) - Vehicle Speed (PCM) - Voltage Fault (PCM) The CTM provides the following messages to other electronic modules over the PCI data bus: Door Ajar Status (EMIC) - Liftgate Ajar Status (EMIC) - Park Brake Status (CAB, EMIC, TCM) - Radio Mode (Radio) - Radio Preset Scan (Radio) - Radio Seek Down (Radio) - Radio Seek Up (Radio) - Radio Volume Down (Radio) - Radio Volume Up (Radio) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Testing and Inspection > Audible Warning Device Control Module: Testing and Inspection "Low Line" Central Timer Module (Chime) Test For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. See: Body and Frame/Body Control Systems/Central Timer Module The hard wired inputs to and outputs from the Central Timer Module (CTM) may be diagnosed and tested using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the CTM. In order to obtain conclusive testing of the CTM, the Programmable Communications Interface (PCI) data bus network and all of the electronic modules that provide inputs to or receive outputs from the CTM must also be checked. The most reliable, efficient, and accurate means to diagnose the CTM, the PCI data bus network, and the electronic modules that provide inputs to or receive outputs from the CTM requires the use of a DRB III scan tool. Refer to the appropriate diagnostic information. The DRB III scan tool can provide confirmation that the PCI data bus network is functional, that all of the electronic modules are sending and receiving the proper messages over the PCI data bus, and that the CTM is receiving the proper hard wired inputs and responding with the proper hard wired outputs needed to perform its many functions. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: The following tests may not prove conclusive in the diagnosis of the Central Timer Module (CTM). The most reliable, efficient, and accurate means to diagnose the CTM requires the use of a DRB III scan tool. Refer to the appropriate diagnostic information. 1. Check the fused B(+) fuses (Fuse 3 - 20 ampere, and Fuse 12 - 20 ampere) in the Power Distribution Center (PDC). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fused B(+) fuses (Fuse 3 - 20 ampere, and Fuse 12 - 20 ampere) in the PDC. If OK, go to Step 3. If not OK, repair the open B(+) circuit between the PDC and the battery as required. 3. Disconnect and isolate the battery negative cable. Disconnect the instrument panel wire harness connector (Connector C3) for the CTM from the CTM connector receptacle. Reconnect the battery negative cable. Check for battery voltage at each of the two fused B(+) circuit cavities of the instrument panel wire harness connector (Connector C3) for the CTM. If OK, disconnect and isolate the battery negative cable, reconnect the instrument panel wire harness connector (Connector C3) for the CTM to the CTM connector receptacle, and go to Step 4. If not OK, repair the open fused B(+) circuit(s) between the CTM and the PDC as required. 4. Check the fused ignition switch output (run-start) fuse (Fuse 11 - 10 ampere) and the fused ignition switch output (run-acc) fuse (Fuse 5 - 20 ampere) in the Junction Block (JB). If OK, go to Step 5. If not OK, repair the shorted circuit or component as required and replace the faulty fuse(s). 5. Reconnect the battery negative cable. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run-start) fuse (Fuse 11 - 10 ampere) and the fused ignition switch output (run-acc) fuse (Fuse 5 20 ampere) in the JB. If OK, go to Step 6. If not OK, repair the open fused ignition switch output (run-start) circuit or fused ignition switch output (run-acc) circuit between the JB and the ignition switch as required. 6. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the instrument panel wire harness connector (Connector C1) for the CTM from the CTM connector receptacle. Reconnect the battery negative cable. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run-start) circuit cavity and the fused ignition switch output (run-acc) cavity of the instrument panel wire harness connector (Connector C1) for the CTM. If OK, go to Step 7. If not OK, repair the open fused ignition switch output (run-start) circuit or fused ignition switch output (run-acc) circuit between the CTM and the JB as required. 7. Turn the ignition switch to the OFF position. Check for continuity between each of the three ground circuits in the instrument panel wire harness connector (Connector C1) for the CTM and a good ground. In each case there should be continuity. If OK, use a DRB III scan tool to perform further diagnosis of the CTM. Refer to the appropriate diagnostic information. If not OK, repair the open ground circuit(s) to ground (G207 or G208) as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Testing and Inspection > Page 7254 Audible Warning Device Control Module: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: Before replacing a Central Timer Module (CTM), use a DRB III scan tool to retrieve the current settings for the CTM programmable features. Refer to the appropriate diagnostic information. These settings should be duplicated in the replacement CTM using the DRB III scan tool before returning the vehicle to service. 1. Disconnect and isolate the battery negative cable. 2. Remove the trim from the left cowl side inner panel. Fig. 2 Central Timer Module 3. Disconnect the two instrument panel wire harness connectors and one body wire harness connector from the CTM connector receptacles (Fig. 2). 4. Remove the three screws that secure the CTM to the left cowl side inner panel. 5. Remove the CTM from the left cowl side inner panel. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: Before replacing a Central Timer Module (CTM), use a DRB III scan tool to retrieve the current settings for the CTM programmable features. Refer to the appropriate diagnostic information. These settings should be duplicated in the replacement high-line/premium CTM using the DRB III scan tool before returning the vehicle to service. 1. Position the CTM onto the left cowl side inner panel (Fig. 2). 2. Install and tighten the three screws that secure the CTM to the left cowl side inner panel. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the two instrument panel wire harness connectors and one body wire harness connector to the CTM connector receptacles. 4. Reinstall the trim onto the left cowl side inner panel. 5. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Locations Brake Warning Indicator: Locations The brake indicator is located in the Information Center area of the instrument cluster; to the right of center. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Locations > Page 7258 Brake Warning Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Brake Warning ..................................................................................................................................... .............................................................. PC194 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Locations > Page 7259 Brake Warning Indicator: Description and Operation BRAKE/PARK BRAKE INDICATOR A brake indicator is standard equipment on all instrument clusters. The brake indicator is located in the Information Center area of the instrument cluster; to the right of center. The brake indicator consists of a stenciled cutout of the word "BRAKE" and the International Control and Display Symbol icons for "Brake Failure" and "Parking Brake" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red lens behind the cutout in the opaque layer of the overlay causes the "BRAKE" text and the two icons to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by a Light Emitting Diode (LED) soldered onto the instrument cluster electronic circuit board. The brake indicator is serviced as a unit with the instrument cluster. The brake indicator gives an indication to the vehicle operator when the parking brake is applied, or when there are certain brake hydraulic system malfunctions. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming, and electronic messages received by the cluster from the Central Timer Module (CTM) and the Controller Antilock Brake (CAB) over the Programmable Communications Interface (PCI) data bus. The brake indicator Light Emitting Diode (LED) receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions; therefore, the LED will always be OFF when the ignition switch is in any position except ON or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the brake indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the brake indicator is illuminated by the instrument cluster for about four seconds as a bulb test. - Brake Lamp-On Message - Each time the cluster receives a lamp-on message from the CTM or the CAB, the brake indicator will be illuminated. If the park brake is applied or not fully released, or if the pressures in the two halves of the split brake hydraulic system are not equal with the ignition switch in the ON position, the brake indicator is illuminated solid. The brake indicator will blink ON and OFF repeatedly when the park brake is applied or not fully released and the ignition switch is in the ON position if the automatic transmission is not in Park or Neutral. The indicator remains illuminated until the cluster receives lamp-off messages from both the CTM and the CAB, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the instrument cluster is put through the actuator test, the brake indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The park brake switch on the park brake pedal mechanism provides a hard wired ground input to the CTM circuitry through the park brake switch sense circuit whenever the park brake is applied or not fully released. The CTM then sends the proper lamp-ON or lamp-OFF messages to the instrument cluster. The brake pressure switch on the brake combination valve provides a hard wired ground input to the CAB circuitry through the brake pressure switch sense circuit whenever the pressures in the two halves of the split brake hydraulic system are unequal. The CAB then sends the proper lamp-ON or lamp-OFF messages to the instrument cluster. If the CAB sends a lamp-ON message after the bulb test, it indicates that the CAB has detected a brake hydraulic system malfunction and/or that the ABS system has become inoperative. The CAB will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. The park brake switch input to the CTM and the brake pressure switch input to the CAB can be diagnosed using conventional diagnostic tools and methods. For proper diagnosis of the antilock brake system, the CTM, the CAB, the PCI data bus, or the message inputs to the instrument cluster that control the brake indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component Information > Locations Check Gauges Lamp: Locations The check gauges indicator is located in the Information Center area of the instrument cluster, to the right of center. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component Information > Locations > Page 7263 Check Gauges Lamp: Description and Operation A check gauges indicator is standard equipment on all instrument clusters. The check gauges indicator is located in the Information Center area of the instrument cluster, to the right of center. The check gauges indicator consists of a stenciled cutout of the words "CHECK GAGES" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red lens behind the cutout in the opaque layer of the overlay causes the "CHECK GAGES" text to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by a Light Emitting Diode (LED) soldered onto the instrument cluster electronic circuit board. The check gauges indicator is serviced as a unit with the instrument cluster. The check gauges indicator gives an indication to the vehicle operator when certain instrument cluster gauge readings reflect a condition requiring immediate attention. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The check gauges indicator Light Emitting Diode (LED) receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions; therefore, the LED will always be OFF when the ignition switch is in any position except ON or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the check gauges indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the check gauges indicator is illuminated for about two seconds as a bulb test. - Engine Temperature High Message - Each time the cluster receives a message from the PCM indicating the engine coolant temperature is about 122 °C (253 °F) or higher, the check gauges indicator will be illuminated. The indicator remains illuminated until the cluster receives a message from the PCM indicating that the temperature is about 119 °C (246 °F) or lower, or until the ignition switch is turned to the OFF position, whichever occurs first. - Engine Oil Pressure Low Message - Each time the cluster receives a message from the PCM indicating the engine oil pressure is about 3.45 kPa (0.5 psi) or lower, the check gauges indicator will be illuminated. The indicator remains illuminated until the cluster receives a message from the PCM indicating that the engine oil pressure is above 3.45 kPa (0.5 psi), or until the ignition switch is turned to the OFF position, whichever occurs first. The cluster will only turn the indicator ON in response to an engine oil pressure low message if the engine speed is greater than zero. - System Voltage Low Message - Each time the cluster receives a message from the PCM indicating the electrical system voltage is less than 11.5 volts, the check gauges indicator will be illuminated. The indicator remains illuminated until the cluster receives a message from the PCM indicating the electrical system voltage is greater than 12.0 volts (but less than 16.6 volts), or until the ignition switch is turned to the OFF position, whichever occurs first. - System Voltage High Message - Each time the cluster receives a message from the PCM indicating the electrical system voltage is greater than 16.6 volts, the check gauges indicator will be illuminated. The indicator remains illuminated until the cluster receives a message from the PCM indicating the electrical system voltage is less than 16.1 volts (but greater than 11.5 volts), or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the engine temperature, oil pressure, and electrical system voltage, then sends the proper messages to the instrument cluster. For further diagnosis of the check gauges indicator or the instrument cluster circuitry that controls the LED, (Refer to ELECTRICAL/INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the PCM, the PCI data bus, or the message inputs to the instrument cluster that control the check gauges indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7268 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7269 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7270 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7271 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7272 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7273 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7274 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7275 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7276 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7277 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7278 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7279 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7280 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7281 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7282 Cigarette Lighter: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7283 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7284 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7285 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 7286 Cigarette Lighter: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Cigar Lighter ........................................................................................................................................ ................................................................... 161 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations Compass: Locations Compass Mini-Trip Computer (CMTC) is located in the overhead console, Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations > Page 7290 Compass: Description and Operation COMPASS/MINI-TRIP COMPUTER The Compass/Mini-Trip Computer is located in the overhead console on models equipped with this option. The compass mini-trip computer units include the electronic control module, a Vacuum-Fluorescent Display (VFD), a compass sensor unit and two push button function switches. The Compass/Mini-Trip Computer module contains a central processing unit and interfaces with other electronic modules in the vehicle on the Programmable Communication Interface (J1850) data bus network. The J1850 data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. The Compass/Mini-Trip Computer provides several electronic functions and features. Some of the functions and features that the compass mini-trip computer module supports and/or controls, include the following display options: Compass and Temperature - provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. - Trip Odometer (ODO) - shows the distance travelled since the last trip computer reset. - Average Fuel Economy (AVG ECO) - shows the average fuel economy since the last trip computer reset. - Instant Fuel Economy (ECO) - shows the present fuel economy based upon the current vehicle distance and fuel used information. - Distance To Empty (DTE) - shows the estimated distance that can be travelled with the fuel remaining in the fuel tank. This estimated distance is computed using the average miles-per-gallon from the last 30 gallons of fuel used. - Elapsed Time (ET) - shows the accumulated ignition-on time since the last trip computer reset. - Blank Screen - the compass mini-trip VFD is turned OFF. The Compass/Mini-Trip Computer uses two push buttons to toggle the display and reset various functions. These push buttons include: Step Button - Press this button to cycle through all the mini-trip computer displays. - US/M Button - Press this button to convert all vehicle displays from US to Metric to US. The Compass/Mini-Trip Computer module cannot be repaired, and is available for service only as a unit. This unit includes the push button switches and the plastic module and display lens. If any of these components is faulty or damaged, the complete compass mini-trip computer module must be replaced. To Reset the Display Press the Step and US/M buttons simultaneously for at least two seconds and all resettable conditions will be reset. This will occur only if a resettable function (AVG ECO, ECO, ET) is currently being displayed. Ambient Temperature Sensor The ambient temperature sensor is hard wired to the HVAC control head. Data input for all other Compass/Mini-Trip Computer functions, including VFD dimming level, is received through J1850 data bus messages. The Compass/Mini-Trip Computer uses its internal programming and all of these inputs to calculate and display the requested data. If the data displayed is incorrect, perform the self-diagnostic tests. If these tests prove inconclusive, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended for further testing of the compass mini-trip computer module and the J1850 data bus. COMPASS While in the compass/temperature mode, the compass will display the direction in which the vehicle is pointed using the eight major compass headings (Examples: north is N, northeast is NE). The self-calibrating compass unit requires no adjusting in normal use. The only calibration that may prove necessary is to drive the vehicle in three complete circles, on level ground, in not less than 48 seconds. This will reorient the compass unit to its vehicle. The compass unit also will compensate for magnetism the body of the vehicle may acquire during normal use. However, avoid placing anything magnetic directly on the roof of the vehicle. Magnetic mounts for an antenna, a repair order hat, or a funeral procession flag can exceed the compensating ability of the compass unit if placed on the roof panel. Magnetic bit drivers used on the fasteners that hold the overhead console assembly to the roof header can also affect compass operation. If the vehicle roof should become magnetized, the demagnetizing and calibration procedures found may be required to restore proper compass operation. The Compass/Mini-Trip Computer only operates with the ignition switch in the ON position. When the ignition switch is turned to the ON position, all of the segments in the Compass/Mini-Trip Computer VFD will be turned OFF for one second, then the display will return to the last function being displayed before the ignition was turned to the OFF position. With the ignition switch in the ON position, momentarily depressing and releasing the Step push button switch will cause the Compass/Mini-Trip Computer to change its mode of operation, and momentarily depressing and releasing the U.S./Metric push button will cause the unit to toggle between U.S. and Metric measurements. This Compass/Mini-Trip Computer features several functions that can be reset. If both the Step and U.S/Metric push buttons are depressed at the same time for more than one second with the ignition switch in the ON position, the trip computer information that can be reset is reset. However, the reset will only occur if the function currently displayed is a function that can be reset. The functions that can be reset are: TRIP ODO, AVG ECO, and ET. For more information on the features and control functions of the Compass/Mini-Trip Computer, see the owner's manual in the vehicle glove box. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations > Page 7291 Automatic Compass Calibration This compass is self calibrating which eliminates the need to manually set the compass. When the vehicle is new, the compass may appear erratic and the CAL symbol will be displayed. After completing three 360' turns in an area free from large metal or metallic objects, the CAL symbol will turn OFF and the compass will function normally. Compass Variance Compass Variance is the difference between Magnetic North and Geographic North. In some areas of the country, the difference between Magnetic and Geographic North is great enough to cause the compass to give false readings. If this occurs, the compass variance must be set. To Set The Variance Turn the ignition ON and set display to Comp./Temp. while pressing the US/M button, press the STEP button for approximately five seconds. The "VAR" symbol will light and the last variance zone number will be displayed. Press the US/Metric Button to select the proper variance zone as shown on the map. Press the Step button to set the new variance zone and resume normal operation. THERMOMETER The thermometer displays the outside ambient temperature in whole degrees. The temperature display can be changed from Fahrenheit to Celsius using the U.S./Metric push button. The displayed temperature is not an instant reading of conditions, but an average temperature. It may take the thermometer display several minutes to respond to a major temperature change, such as driving out of a heated garage into winter temperatures. When the ignition switch is turned to the OFF position, the last displayed temperature reading stays in the thermometer unit memory. When the ignition switch is turned to the ON position again, the thermometer will display the memory temperature if the engine coolant temperature is above about 52 °C (125 °F). If the engine coolant temperature is below about 52 °C (125 °F), the thermometer will display the actual temperature sensed by the ambient temperature sensor. The thermometer temperature display update interval varies with the vehicle speed. The thermometer function is supported by an ambient temperature sensor. The sensor is mounted outside the passenger compartment near the front and center of the vehicle, and is hard wired to the HVAC control head which sends temperature on J1850 data bus circuit. The ambient temperature sensor is available as a separate service item. NOTE: The compass mini-trip computer will display "OC" for temperatures below -40 °C and "SC" for temperatures above 55 °C. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations > Page 7292 Compass: Testing and Inspection If the problem with the compass mini-trip computer module is an "OC" or "SC" in the compass/thermometer display, refer to Ambient Temperature Sensor in the Diagnosis and Testing. If the problem with the compass mini-trip computer module is an inaccurate or scrambled display, refer to Self-Diagnostic Test in the Diagnosis and Testing. If the problem with the compass mini-trip computer module is incorrect Vacuum Fluorescent Display (VFD) dimming levels, use a DRB scan tool and the proper Diagnostic Procedures to test for the correct dimming message inputs being received from the instrument cluster over the J1850 data bus. If the problem is a no-display condition, use the following procedures. 1. Check the fused ignition switch output (run/start) fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run/start) fuse in the junction block. If OK, go to Step 3. If not OK, repair the open fused ignition switch output (run/start) circuit to the ignition switch as required. 3. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Remove the overhead console. Check for continuity between the ground circuit cavities of the roof wire harness connector for the overhead console and a good ground. There should be continuity. If OK, go to Step 4. If not OK, repair the open ground circuit to ground as required. 4. Connect the battery negative cable. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run/start) circuit cavity of the roof wire harness connector for the overhead console. If OK, refer to Self-Diagnostic Test in the Diagnosis and Testing for further diagnosis of the compass mini-trip computer module and the J1850 data bus. If not OK, repair the open fused ignition switch output (run/start) circuit to the junction block fuse as required. Self-Check Diagnostics A self-diagnostic test is used to determine that the compass mini-trip computer module is operating properly electrically. Initiate the self-diagnostic test as follows: 1. With the ignition switch in the OFF position, simultaneously depress and hold the Step button and the U.S./Metric button while rotating the ignition switch to the ON position.. 2. Continue to hold both buttons depressed until the compass mini-trip computer module enters the display segment test. In this test, all of the Vacuum Fluorescent Display (VFD) segments are lighted while the compass mini-trip computer module performs the following checks: Non-Volatile Memory Test (EEPROM) - Asic Communications Test - Vref Voltage Test. - Compass Test - J1850 Communications Test 3. Following completion of these tests, the compass mini-trip computer will return to normal operation or display one of two messages: "FML" or "BUS." Respond to these test results as follows: If no test result message is displayed, but compass mini-trip computer operation is still improper, the use of a DRB scan tool and the proper Diagnostic Procedures are required for further diagnosis. - If the "FAIL" message is displayed, the compass mini-trip computer module is faulty and must be replaced. - If the "BUS" message is displayed, one or more of the required J1850 messages are not present (see list below) and the use of a DRB scan tool and the proper Diagnostic Procedures are required for further diagnosis. - If any VFD segment should fail to light during the display segment test, the compass mini-trip computer module is faulty and must be replaced. 4. If the first five tests pass, the Compass mini- trip computer shall verify that all the required J1850 messages are present on the J1850 bus. If all required J1850 messages are present on the J1850 bus, or if the ignition switch is turned to the OFF position, the compass mini-trip computer module will automatically return to normal operation. The required J1850 messages are: Dimming message - Fuel Used message - Distance Pulses message - Percentage Fuel Tank Full message - Fuel Type message - VIN (Vehicle Identification Number) - Vehicle Speed message - Engine gauge data (Coolant temperature data) NOTE: The Fuel Used J1850 message shall be ignored if the engine type is Diesel or Compressed Natural Gas. - Pressing the STEP or US/M switches during any portion of the testing procedure will cause the compass mini-trip computer to exit diagnostics and return to compass/temperature mode. - If the compass functions, but accuracy is suspect, it may be necessary to perform a variation adjustment. This procedure allows the compass unit to accommodate variations in the earth's magnetic field strength, based on geographic location. Refer to Compass Variation Adjustment in the Service Procedures. - If the compass reading has blanked out, and only "CAL" appears in the display, demagnetizing may be necessary to remove excessive residual magnetic fields from the vehicle. Refer to Compass Demagnetizing in the Service Procedures. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations > Page 7293 Compass: Adjustments Compass variance, also known as magnetic declination, is the difference in angle between magnetic north and true geographic north. In some geographic locations, the difference between magnetic and geographic north is great enough to cause the compass to give false readings. If this problem occurs, the compass variance must be set. Fig. 1 Variance Settings To set the compass variance: 1. Using the Variance Settings map, find your geographic location and note the zone number (Fig. 1). 2. Turn the ignition switch to the ON position. If the compass/temperature data is not currently being displayed, momentarily depress and release the Step push button to step through the display options until you have reached the compass/temperature display. 3. Depress both the U.S./Metric, and the Step push buttons and hold the buttons down until "WAR" appears in the display. This takes about five seconds. 4. Release both of the push buttons. "WAR" along with the current variance zone will appear in the display. 5. Momentarily depress and release the U.S./Metric push button to step through the zone numbers, until the zone number for your geographic location appears in the display. 6. Momentarily depress and release the Step push button to enter the displayed zone number into the compass unit memory. 7. Confirm that the correct directions are now indicated by the compass. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Calibration Compass: Service and Repair Compass Calibration CAUTION: Do not place any external magnets, such as magnetic roof mount antennas, in the vicinity of the compass. Do not use magnetic tools when servicing the overhead console. The electronic compass unit features a self-calibrating design, which simplifies the calibration procedure. This feature automatically updates the compass calibration while the vehicle is being driven. This allows the compass unit to compensate for small changes in the residual magnetism that the vehicle may acquire during normal use. If the compass readings appear to be erratic or out of calibration, perform the following calibration procedure. Also, new service replacement compass mini-trip computer modules must have their compass calibrated using this procedure. Do not attempt to calibrate the compass near large metal objects such as other vehicles, large buildings, or bridges; or, near overhead or underground power lines. NOTE: Whenever the compass is calibrated manually, the variation number must also be reset. See Compass Variation Adjustment in the Service Procedures. Calibrate the compass manually as follows: 1. Turn the ignition switch to the ON position. If the compass/temperature data is not currently being displayed, momentarily depress and release the Step push button to step through the display options until you have reached the compass/temperature display. 2. Depress both the U.S./Metric and the Step push buttons. Hold the push buttons down until "CAL" appears in the display. This takes about ten seconds, and appears about five seconds after 'WAR" is displayed. 3. Release both of the push buttons. 4. Drive the vehicle on a level surface, away from large metal objects and power lines, through three or more complete circles in not less than 48 seconds. The "CAL" message will disappear from the display to indicate that the compass is now calibrated. NOTE: If the "CAL" message remains in the display, either there is excessive magnetism near the compass, or the unit is faulty. Repeat the calibration procedure at least one more time. - If the wrong direction is still indicated in the compass display, the area selected for calibration may be too close to a strong magnetic field. Repeat the calibration procedure in another location. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Calibration > Page 7296 Compass: Service and Repair Compass Demagnetizing A degaussing tool (Special Tool 6029) is used to demagnetize, or degauss, the overhead console forward mounting screw and the roof panel above the overhead console. Equivalent units must be rated as continuous duty for 110/115 volts and 60 Hz. They must also have a field strength of over 350 gauss at 7 millimeters (0.25 inch) beyond the tip of the probe. To demagnetize the roof panel and the overhead console forward mounting screw, proceed as follows: 1. Be certain that the ignition switch is in the OFF position, before you begin the demagnetizing procedure. 2. Connect the degaussing tool to an electrical outlet, while keeping the tool at least 61 centimeters (2 feet) away from the compass unit. 3. Slowly approach the head of the overhead console forward mounting screw with the degaussing tool connected. 4. Contact the head of the screw with the plastic coated tip of the degaussing tool for about two seconds. 5. With the degaussing tool still energized, slowly back it away from the screw. When the tip of the tool is at least 61 centimeters (2 feet) from the screw head, disconnect the tool. Fig.2 Roof Demagnetizing Pattern 6. Place a piece of paper approximately 22 by 28 centimeters (8.5 by 11 inches), oriented on the vehicle lengthwise from front to rear, on the center line of the roof at the windshield header (Fig. 2). The purpose of the paper is to protect the roof panel from scratches, and to define the area to be demagnetized. 7. Connect the degaussing tool to an electrical outlet, while keeping the tool at least 61 centimeters (2 feet) away from the compass unit. 8. Slowly approach the center line of the roof panel at the windshield header, with the degaussing tool connected. 9. Contact the roof panel with the plastic coated tip of the degaussing tool. Be sure that the template is in place to avoid scratching the roof panel. Using a slow, back-and-forth sweeping motion, and allowing 13 millimeters (0.50 inch) between passes, move the tool at least 11 centimeters (4 inches) to each side of the roof center line, and 28 centimeters (11 inches) back from the windshield header. 10. With the degaussing tool still energized, slowly back it away from the roof panel. When the tip of the tool is at least 61 centimeters (2 feet) from the roof panel, disconnect the tool. 11. Calibrate the compass and adjust the compass variance. Refer to Compass Variation Adjustment and Compass Calibration in the Service Procedures for the procedures. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Calibration > Page 7297 Compass: Service and Repair Compass/Mini-Trip Computer Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console from the headliner. Refer to Overhead Console in the Removal and Installation for the procedures. Compass Mini-Trip Computer Remove/Install 3. Remove the four screws that secure the compass mini-trip computer module to the overhead console housing (Fig. 5). 4. Pull the compass mini-trip computer module away from the overhead console far enough to access the wire harness connectors. 5. Disengage the overhead console wire harness connector from the mount on the compass mini-trip computer module housing by pushing the connector firmly toward the left side of the overhead console housing. 6. Disconnect the overhead console wire harness connector from the compass mini-trip computer module connector receptacle. 7. Remove the compass mini-trip computer module from the overhead console housing. INSTALLATION 1. Position the compass mini-trip computer module onto the overhead console housing. 2. Reconnect the overhead console wire harness connector to the compass mini-trip computer module connector receptacle. 3. Engage the overhead console wire harness connector onto the mount on the compass mini-trip computer module housing by aligning the channels on the connector with the tab on the mount and pushing the connector firmly toward the right side of the overhead console housing. 4. Install and tighten the four screws that secure the compass mini-trip computer module to the overhead console housing. Tighten the screws to 2.2 Nm (20 in. lbs.). 5. Install the overhead console onto the headliner. Refer to Overhead Console in the Removal and Installation for the procedures. 6. Reconnect the battery negative cable. NOTE: If a new compass mini-trip computer has been installed, the compass will have to be calibrated and the variance set. Refer to Compass Variation Adjustment and Compass Calibration in the Service Procedures for the procedures. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cruise Control Indicator Lamp > Component Information > Description and Operation Cruise Control Indicator Lamp: Description and Operation A cruise indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional speed control system, this indicator is electronically disabled. The cruise indicator consists of the word "CRUISE", which appears in the lower portion of the odometer/trip odometer Vacuum-Fluorescent Display (VFD). The VFD is part of the cluster electronic circuit board, and is visible through a cutout located in the lower left corner of the cluster overlay. The dark lens of the VFD prevents the indicator from being clearly visible when it is not illuminated. The word "CRUISE" appears in an amber color and at the same lighting level as the odometer/trip odometer information when it is illuminated by the instrument cluster electronic circuit board. The cruise indicator is serviced as a unit with the VFD in the instrument cluster. The cruise indicator gives an indication to the vehicle operator when the speed control system is turned ON, regardless of whether the speed control is engaged. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The cruise indicator receives battery current ON the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions; therefore, the indicator will always be OFF when the ignition switch is in any position except ON or Start. The indicator only illuminates when it is switched to ground by the instrument cluster circuitry. The instrument cluster will turn ON the cruise indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the cruise indicator is illuminated for about two seconds as a bulb test. - Cruise Lamp-ON Message - Each time the cluster receives a cruise lamp-ON message from the PCM indicating the speed control system has been turned ON, the cruise indicator is illuminated. The indicator remains illuminated until the cluster receives a cruise lamp-OFF message from the PCM or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the cruise indicator will be turned ON, then OFF again during the VFD portion of the test to confirm the functionality of the VFD, and again during the bulb check portion of the test to confirm the functionality of the cluster control circuitry. The PCM continually monitors the speed control switches to determine the proper outputs to the speed control servo. The PCM then sends the proper cruise indicator lamp-ON and lamp-OFF messages to the instrument cluster. For further diagnosis of the cruise indicator or the instrument cluster circuitry that controls the indicator, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the speed control system, the PCM, the PCI data bus, or the message inputs to the instrument cluster that control the cruise indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 7305 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Locations Door/Trunk Ajar Indicator/Lamp: Locations The door ajar indicator is located in the Information Center area of the instrument cluster, to the left of center. The liftgate ajar indicator is located in the Information Center area of the instrument cluster, to the left of center. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Locations > Page 7309 Liftgate Lamp Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Locations > Page 7310 Door/Trunk Ajar Indicator/Lamp: Description and Operation DOOR AJAR INDICATOR A door ajar indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with this optional feature, this indicator is electronically disabled. The door ajar indicator is located in the Information Center area of the instrument cluster, to the left of center. The door ajar indicator consists of a stenciled cutout of the words "DOOR AJAR" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red lens behind the cutout in the opaque layer of the overlay causes the "DOOR AJAR" text to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by a Light Emitting Diode (LED) soldered onto the instrument cluster electronic circuit board. The door ajar indicator is serviced as a unit with the instrument cluster. The door ajar indicator gives an indication to the vehicle operator that one or more of the passenger compartment doors may be open or not completely latched. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Central Timer Module (CTM) over the Programmable Communications Interface (PCI) data bus. The door ajar indicator Light Emitting Diode (LED) receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions; therefore, the LED will always be OFF when the ignition switch is in any position except ON or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the door ajar indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the door ajar indicator is illuminated for about two seconds as a bulb test. - Door Ajar Lamp-ON Message - Each time the cluster receives a door ajar lamp-ON message from the CTM indicating that a door is open or not completely latched, the door ajar indicator will be illuminated. The indicator remains illuminated until the cluster receives an door ajar lamp-OFF message from the CTM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the door ajar indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the cluster control circuitry. The CTM continually monitors the door ajar switches to determine the status of the doors. The CTM then sends the proper door ajar lamp-on and lamp-off messages to the instrument cluster. For further diagnosis of the door ajar indicator or the instrument cluster circuitry that controls the indicator, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the door ajar switches and circuits, (Refer to LAMPS/LIGHTING - INTERIOR/DOOR AJAR SWITCH DIAGNOSIS AND TESTING). For proper diagnosis of the CTM, the PCI data bus, or the message inputs to the instrument cluster that control the door ajar indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. LIFTGATE AJAR INDICATOR A liftgate ajar indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with this optional feature, this indicator is electronically disabled. The liftgate ajar indicator is located in the Information Center area of the instrument cluster, to the left of center. The liftgate ajar indicator consists of a stenciled cutout of the words "GATE OPEN" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red lens behind the cutout in the opaque layer of the overlay causes the "GATE OPEN" text to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by a Light Emitting Diode (LED) soldered onto the instrument cluster electronic circuit board. The liftgate ajar indicator is serviced as a unit with the instrument cluster. The liftgate ajar indicator gives an indication to the vehicle operator that the passenger compartment liftgate may be open or not completely latched. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Central Timer Module (CTM) over the Programmable Communications Interface (PCI) data bus. The liftgate ajar indicator Light Emitting Diode (LED) receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions; therefore, the LED will always be OFF when the ignition switch is in any position except ON or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the liftgate ajar indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the liftgate ajar indicator is illuminated for about two seconds as a bulb test. - Liftgate Ajar Lamp-ON Message - Each time the cluster receives a liftgate ajar lamp-ON message from the CTM indicating that the liftgate is open or not completely latched, the liftgate ajar indicator will be illuminated. The indicator remains illuminated until the cluster receives an liftgate ajar lamp-OFF message from the CTM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the liftgate ajar indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the cluster control circuitry. The CTM continually monitors the liftgate ajar switch to determine the status of the liftgate. The CTM then sends the proper liftgate ajar lamp-ON and lamp-OFF messages to the instrument cluster. For further diagnosis of the liftgate ajar indicator or the instrument cluster circuitry that controls the indicator, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the liftgate ajar switch and circuits, Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Locations > Page 7311 (Refer to LIFTGATE AJAR SWITCH - DIAGNOSIS AND TESTING). For proper diagnosis of the CTM, the PCI data bus, or the message inputs to the instrument cluster that control the liftgate ajar indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions Door Switch: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7316 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7317 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7318 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7319 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7320 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7321 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7322 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7323 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7324 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7325 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7326 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7327 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7328 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7329 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7330 Door Switch: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7331 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7332 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7333 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7334 Door Switch: Connector Views Driver Door Power Lock Motor/Ajar Switch Left Rear Door Power Lock Motor/Ajar Switch Passenger Door Power Lock Motor/Ajar Switch Right Rear Door Power Lock Motor/Ajar Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7335 Door Ajar Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Page 7336 Door Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Page 7337 Door Switch: Description and Operation DOOR AJAR SWITCH The door ajar switches are integral to the door latches on each door. The switches close a path to ground for the Central Timer Module (CTM) when a door is opened, and open the ground path when a door is closed. The door ajar switches cannot be repaired and, if faulty or damaged, the door latch unit must be replaced. The door ajar switches close a path to ground for the Central Timer Module (CTM) when a door is opened, and opens the ground path when a door is closed. The passenger side front door and both rear door ajar switches are connected in a parallel-series circuit between ground and the CTM, while the driver side front door ajar switch is connected in series between ground and the CTM to provide a unique input. The CTM reads the switch status through an internal pull-up, then sends the proper switch status messages to other electronic modules over the Programmable Communications Interface (PCI) data bus network. The door ajar switches can be diagnosed using conventional diagnostic tools and methods. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Page 7338 Door Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Disconnect the door latch pigtail wire connector from the door wire harness connector. Check for continuity between the ground circuit cavity in the door wire harness connector and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the open ground circuit to ground as required. 2. Check for continuity between the ground circuit cavity and the driver or passenger door ajar switch sense circuit cavity in the door latch pigtail wire connector. There should be continuity with the door opened, and no continuity with the door closed. If OK, go to Step 3. If not OK, replace the faulty door latch unit. 3. Disconnect the body wire harness connector (Connector C2) for the Central Timer Module (CTM) from the CTM connector receptacle. Check for continuity between the driver or passenger door ajar switch sense circuit cavity of the body wire harness connector (Connector C2) and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, repair the shorted driver or passenger door ajar switch sense circuit between the door latch and the CTM as required. 4. Check for continuity between the driver or passenger door ajar switch sense circuit cavities of the body wire harness connector (Connector C2) and the door wire harness connector for the door latch. There should be continuity. If OK, use a DRB III scan tool to diagnose the CTM. Refer to the appropriate diagnostic procedures. If not OK, repair the open driver or passenger door ajar switch sense circuit between the door latch and the CTM as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Customer Interest for Driver/Vehicle Information Display: > 08-006-01 > Mar > 01 > Overhead Console Display - Inaccurate MPG Reading Driver/Vehicle Information Display: Customer Interest Overhead Console Display - Inaccurate MPG Reading NUMBER: 08-006-01 GROUP: Electrical DATE: Mar. 23, 2001 SUBJECT: Inaccurate Miles Per Gallon/Distance To Empty Reading From Overhead Console OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration level 01Cal14) MODELS: 2001 (AN) Dakota 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 4.7L ENGINE. SYMPTOM/CONDITION: The vehicle's overhead console may display a Miles Per Gallon (MPG) that is approximately two MPG higher than what the vehicle actually is getting. Additionally, one of the inputs for the Distance To Empty (DTE) reading is taken from the MPG reading which may cause the DTE reading to be inaccurate. DIAGNOSIS/REPAIR PROCEDURES: Due to the nature of this issue, perform the Repair Procedure on any subject model vehicle in which the customer complains that the vehicle is getting approximately two miles per gallon less than displayed on the overhead console. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRBIII(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR, WHEN USING THE MDS2 AND THE DRBIII(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2077 OR HIGHER. REPAIR PROCEDURE: 1. Reprogram the PCM using the MDS2 (Mopar Diagnostic System) and the DRB III(R) (Scan Tool). NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, 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 WITH A MODULE. 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 ERASED. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Customer Interest for Driver/Vehicle Information Display: > 08-006-01 > Mar > 01 > Overhead Console Display - Inaccurate MPG Reading > Page 7347 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 PCM 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Driver/Vehicle Information Display: > 08-006-01 > Mar > 01 > Overhead Console Display - Inaccurate MPG Reading Driver/Vehicle Information Display: All Technical Service Bulletins Overhead Console Display Inaccurate MPG Reading NUMBER: 08-006-01 GROUP: Electrical DATE: Mar. 23, 2001 SUBJECT: Inaccurate Miles Per Gallon/Distance To Empty Reading From Overhead Console OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration level 01Cal14) MODELS: 2001 (AN) Dakota 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 4.7L ENGINE. SYMPTOM/CONDITION: The vehicle's overhead console may display a Miles Per Gallon (MPG) that is approximately two MPG higher than what the vehicle actually is getting. Additionally, one of the inputs for the Distance To Empty (DTE) reading is taken from the MPG reading which may cause the DTE reading to be inaccurate. DIAGNOSIS/REPAIR PROCEDURES: Due to the nature of this issue, perform the Repair Procedure on any subject model vehicle in which the customer complains that the vehicle is getting approximately two miles per gallon less than displayed on the overhead console. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRBIII(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR, WHEN USING THE MDS2 AND THE DRBIII(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2077 OR HIGHER. REPAIR PROCEDURE: 1. Reprogram the PCM using the MDS2 (Mopar Diagnostic System) and the DRB III(R) (Scan Tool). NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, 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 WITH A MODULE. 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 ERASED. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Driver/Vehicle Information Display: > 08-006-01 > Mar > 01 > Overhead Console Display - Inaccurate MPG Reading > Page 7353 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 PCM 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Page 7354 Driver/Vehicle Information Display: Description and Operation OVERHEAD CONSOLE An overhead console unit is an available factory-installed option on this model The overhead console unit features a garage door opener storage bin, a sunglasses storage bin, two reading and courtesy lamps and either a standard paperclip or an optional compass mini-trip computer. See the owner's manual in the vehicle glove box for more information on the features, use and operation of all of the overhead console components and systems. The overhead console for this model includes two front-mounted reading and courtesy lamps, a sunglasses storage bin, universal transmitter and either a standard paperclip or an optional compass mini-trip computer. The overhead console is secured with two snap clips at the rear and a single screw at the front to the overhead console mounting bracket. The front of the overhead console mounting bracket is secured to the roof header near the windshield with two screws, and the rear of the bracket is secured with double-faced tape to the inside surface of the roof panel. A single electrical connection joins the overhead console wire harness to the roof wire harness. Following are general descriptions of the major components used in the overhead console. See the owner's manual in the vehicle glove box for more information on the use and operation of the various overhead console features. Sunglass Storage Bin A sunglasses storage bin is included in the overhead console. The storage bin is located near the center of the overhead console and is held in the closed position by a spring-loaded latch mechanism that is integral to the storage bin door. The interior of the bin is lined with a foam rubber padding material to protect the sunglasses from being scratched. A damper spring is snapped onto the pivot shaft of the sunglasses storage bin door. The damper spring engages two flats on the shaft and is anchored in a slot in the rear flange of the overhead console reading and courtesy lamp housing to provide a smooth opening action and an open detent position for the storage bin unit. The sunglasses storage bin and door unit is available for service replacement. The bin and door unit includes the spring-loaded latch mechanism, the bin liner and the damper spring. If any of these components is damaged or faulty, the sunglasses storage bin and door unit must be replaced. The sunglasses storage bin is opened by pressing the latch on the rear edge of the door towards the front of the vehicle, then pulling the bin downward to the open detent position. The spring4oaded latch mechanism on the sunglasses bin door will automatically engage when the bin is closed. See the owner's manual in the vehicle glove box for more information on the use and operation of the sunglasses storage bin. Paperclip A paperclip is standard equipment on the base version of the overhead console. The paperclip provides a convenient place for storage and easy retrieval of notes, maps, toll tickets or stubs and other paper items that may be required or desired while driving. The paperclip is located near the front of the overhead console and is secured in the overhead console housing by four screws. The paperclip is available for service replacement, but it cannot be adjusted or repaired. If the paperclip is damaged or faulty it must be replaced. COMPASS/MINI-TRIP COMPUTER The compass mini-trip computer is located in the overhead console on models equipped with this option. The compass mini-trip computer units include the electronic control module, a Vacuum-Fluorescent Display (VFD), a compass sensor unit and two push button function switches. The compass mini-trip computer module contains a central processing unit and interfaces with other electronic modules in the vehicle on the Programmable Communication Interface (J1850) data bus network. The J1850 data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. The compass mini-trip computer provides several electronic functions and features. Some of the functions and features that the compass mini-trip computer module supports and/or controls, include the following display options: Compass and temperature - provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. - Trip Odometer (TRIP ODO) - shows the distance travelled since the last trip computer reset. - Average fuel economy (AVG ECO) - shows the average fuel economy since the last trip computer reset. - Instant fuel economy (ECO) - shows the present fuel economy based upon the current vehicle distance and fuel used information. - Distance To Empty (DTE) - shows the estimated distance that can be travelled with the fuel remaining in the fuel tank. This estimated distance is computed using the average miles-per-gallon from the last 30 gallons of fuel used. - Elapsed Time (ET) - shows the accumulated ignition-on time since the last trip computer reset. - Blank screen - the compass mini-trip VFD is turned OFF. The ambient temperature sensor is hard wired to the IWAC control head. Data input for all other compass mini-trip computer functions, including VFD dimming level, is received through J1850 data bus messages. The compass mini-trip computer uses its internal programming and all of these inputs to calculate and display the requested data. If the data displayed is incorrect, perform the self-diagnostic tests. If these tests prove inconclusive, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended for further testing of the compass mini-trip computer module and the J1850 data bus. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Page 7355 The compass mini-trip computer module cannot be repaired, and is available for service only as a unit. This unit includes the push button switches and the plastic module and display lens. If any of these components is faulty or damaged, the complete compass mini-trip computer module must be replaced. Compass While in the compass/temperature mode, the compass will display the direction in which the vehicle is pointed using the eight major compass headings (Examples: north is N, northeast is NE). The self-calibrating compass unit requires no adjusting in normal use. The only calibration that may prove necessary is to drive the vehicle in three complete circles, on level ground, in not less than forty-eight seconds. This will reorient the compass unit to its vehicle. The compass unit also will compensate for magnetism the body of the vehicle may acquire during normal use. However, avoid placing anything magnetic directly on the roof of the vehicle. Magnetic mounts for an antenna, a repair order hat, or a funeral procession flag can exceed the compensating ability of the compass unit if placed on the roof panel. Magnetic bit drivers used on the fasteners that hold the overhead console assembly to the roof header can also affect compass operation. If the vehicle roof should become magnetized, the demagnetizing and calibration procedures found may be required to restore proper compass operation. The compass mini-trip computer only operates with the ignition switch in the ON position. When the ignition switch is turned to the ON position, all of the segments in the compass mini-trip computer VFD will be turned OFF for one second, then the display will return to the last function being displayed before the ignition was turned to the OFF position. With the ignition switch in the ON position, momentarily depressing and releasing the Step push button switch will cause the compass-mini-trip computer to change its mode of operation, and momentarily depressing and releasing the U.S./Metric push button will cause the unit to toggle between U.S. and Metric measurements. This compass mini-trip computer features several functions that can be reset. If both the Step and U.S/Metric push buttons are depressed at the same time for more than one second with the ignition switch in the On position, the trip computer information that can be reset is reset. However, the reset will only occur if the function currently displayed is a function that can be reset. The functions that can be reset are: TRIP ODO, AVG ECO, and ET. For more information on the features and control functions of the compass mini-trip computer, see the owner's manual in the vehicle glove box. Thermometer The thermometer displays the outside ambient temperature in whole degrees. The temperature display can be changed from Fahrenheit to Celsius using the U.S./Metric push button. The displayed temperature is not an instant reading of conditions, but an average temperature. It may take the thermometer display several minutes to respond to a major temperature change, such as driving out of a heated garage into winter temperatures. When the ignition switch is turned to the OFF position, the last displayed temperature reading stays in the thermometer unit memory. When the ignition switch is turned to the ON position again, the thermometer will display the memory temperature if the engine coolant temperature is above about 52 °C (125 °F). If the engine coolant temperature is below about 52 °C (125 °F), the thermometer will display the actual temperature sensed by the ambient temperature sensor. The thermometer temperature display update interval varies with the vehicle speed. The thermometer function is supported by an ambient temperature sensor. The sensor is mounted outside the passenger compartment near the front and center of the vehicle, and is hard wired to the HVAC control head which sends temperature on J1850 data bus circuit. The ambient temperature sensor is available as a separate service item. NOTE: The compass mini-trip computer will display "OC" for temperatures below -40 °C and "SC" for temperatures above 55 °C. AMBIENT TEMPERATURE SENSOR Ambient air temperature is monitored by the compass mini-trip computer module through the ambient temperature sensor. The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the right side of the radiator yoke, behind the radiator grille and in front of the engine compartment. For complete circuit diagrams, refer to Overhead Console in the Contents of Wiring Diagrams. The ambient temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent to it by the compass mini-trip computer module. The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the compass mini-trip computer module. Based upon the resistance in the sensor, the compass mini-trip computer module senses a specific voltage on the temperature sensor signal circuit, which it is programmed to correspond to a specific temperature. UNIVERSAL TRANSMITTER On some models a Universal Garage Door Opener (UGDO) transceiver is standard factory-installed equipment. The UGDO transceiver is integral to the overhead console. The only visible component of the UGDO are the three transmitter push buttons at the rear of the overhead console. The three UGDO transmitter push buttons are identified with one, two or three raised tactile bumps so that they be easily identified by sight or by feel. Each of the three UGDO transmitter push buttons controls an independent radio transmitter channel. Each of these three channels can be trained to transmit a different radio frequency signal for the remote operation of garage door openers, motorized gate openers, home or Office lighting, security systems or just about any other device that can be equipped with a radio receiver in the 286 to 399 MegaHertz (MHz) frequency range for remote operation. The UGDO is capable of operating systems using either rolling code or non-rolling code technology. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Page 7356 The UGDO cannot be repaired, and is available for service only as a unit. This unit includes the push button switches and the plastic module. The UGDO operates on a non-switched source of battery current so the unit will remain functional, regardless of the ignition switch position. For more information on the features, programming procedures and operation of the UGDO, see the owner's manual in the vehicle glove box. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle Technical Service Bulletin # 08-032-00A Date: 001229 4X4 Service Lamp - ON, 4X2 Vehicle NUMBER: 08-032-00 REV. A GROUP: Electrical DATE: Dec. 29, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-032-00, DATED OCTOBER 20, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS BULLETIN IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS SUBJECT: "Service 4WD" Lamp Illuminated On 4X2 Vehicles OVERVIEW: This bulletin involves installing a revised HVAC control assembly. MODELS: NOTE: THIS BULLETIN APPLIES TO 4X2 VEHICLES BUILT BEFORE OCTOBER 13, 2000 (MDH 1013XX). SYMPTOM/CONDITION: The "Service 4WD" lamp is illuminated even though the truck is not a 4X4 vehicle. DIAGNOSIS: Start the engine. Once the instrument cluster bulb check has been completed, verify that the "Service 4WD" lamp is illuminated. If the "Service 4WD" lamp is illuminated, perform the Repair Procedure. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 7365 FAILURE CODE: Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING INSTRUMENT PANEL COMPONENT SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is equipped with an automatic transmission, turn the ignition switch to the Unlock position, set the park brake, and place the transmission gear selector lever in the LOW position. 3. If the vehicle is equipped with a tilt column, set the tilt steering column in its lowest position. 4. Reach under the left end of the instrument panel to access and unsnap the rod end clip on the park brake release link and disengage the link from the back of the handle (Fig. 1). 5. Remove the three screws that secure the lower edge of the steering column opening cover to the lower instrument panel reinforcement. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 7366 6. Using a trim stick or another suitable wide flat-bladed tool, gently pry the upper edge of the steering column opening cover just below the cluster bezel on each side of the steering column away from the instrument panel far enough to disengage each of the snap clip retainers from their receptacles in the instrument panel base trim (Fig. 2). 7. Remove the steering column opening cover from the instrument panel. 8. Remove the two screws in the hooded area above the instrument cluster that secures the cluster bezel to the instrument panel base trim (Fig. 3). 9. Using a trim stick or another suitable wide flat-bladed tool, gently pry around the perimeter of the cluster bezel to disengage the snap clips from their receptacles in the instrument panel base trim. 10. Pull the right side of the cluster bezel away from the instrument panel far enough to access and disconnect the instrument panel wire harness connector for the headlamp switch from the switch connector receptacle. 11. Pull the left side of the cluster bezel away from the instrument panel far enough to access and disconnect the instrument panel wire harness connectors from the receptacles for the passenger airbag ON/OFF switch (if equipped), the rear window defogger switch (if equipped), the HVAC control, and the transfer case switch (if equipped). 12. Remove the cluster bezel from the instrument panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 7367 13. Remove the four screws that secure the HVAC control to the cluster bezel (Fig. 4). 14. Remove the HVAC control from the instrument panel. 15. Position the new HVAC control (see Parts Required section) in the cluster bezel and secure it with four screws. Tighten the screws to 2.2 Nm (17 i3 in. lbs.) 16. Position the cluster bezel to the instrument panel. 17. Pull the left side of the cluster bezel away from the instrument panel far enough to access and reconnect the instrument panel wire harness connectors to the receptacles for the passenger airbag on/off switch (if equipped), the rear window defogger switch (if equipped), the HVAC control, and the transfer case switch (if equipped). 18. Pull the right side of the cluster bezel away from the instrument panel far enough to access and reconnect the instrument panel wire harness connector for the headlamp switch to the switch connector receptacle. 19. Align the snap clips on the cluster bezel with the receptacles in the instrument panel base trim. 20. Using hand pressure, press firmly on the cluster bezel over each of the snap clip locations until each snap clip is fully engaged in their receptacle. 21. Install and tighten the two screws in the hooded area above the instrument cluster that secure the cluster bezel to the instrument panel base trim (Fig. 3). Tighten the screws to 2.2 Nm (20 in. lbs.). 22. Position the steering column opening cover to the instrument panel. 23. Align the snap clip retainers on the steering column opening cover with the receptacles in the instrument panel base trim. 24. Using hand pressure, press firmly on the steering column opening cover over the snap clip locations until each of the snap clips are fully engaged in their receptacle. 25. Install and tighten the three screws that secure the lower edge of the steering column opening cover to the instrument structural support. Tighten the screws to 2.2 Nm (20 in.lbs.). 26. Reach under the left end of the instrument panel to access and engage the park brake release link to the back of the handle. Then snap the rod end clip over the park brake release link to secure the connection. 27. Reconnect the battery negative cable. 28. On vehicles equipped with A/C, perform the A/C cool down test using the DRBIII(R). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle Technical Service Bulletin # 08-032-00A Date: 001229 4X4 Service Lamp - ON, 4X2 Vehicle NUMBER: 08-032-00 REV. A GROUP: Electrical DATE: Dec. 29, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-032-00, DATED OCTOBER 20, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS BULLETIN IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS SUBJECT: "Service 4WD" Lamp Illuminated On 4X2 Vehicles OVERVIEW: This bulletin involves installing a revised HVAC control assembly. MODELS: NOTE: THIS BULLETIN APPLIES TO 4X2 VEHICLES BUILT BEFORE OCTOBER 13, 2000 (MDH 1013XX). SYMPTOM/CONDITION: The "Service 4WD" lamp is illuminated even though the truck is not a 4X4 vehicle. DIAGNOSIS: Start the engine. Once the instrument cluster bulb check has been completed, verify that the "Service 4WD" lamp is illuminated. If the "Service 4WD" lamp is illuminated, perform the Repair Procedure. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 7373 FAILURE CODE: Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING INSTRUMENT PANEL COMPONENT SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is equipped with an automatic transmission, turn the ignition switch to the Unlock position, set the park brake, and place the transmission gear selector lever in the LOW position. 3. If the vehicle is equipped with a tilt column, set the tilt steering column in its lowest position. 4. Reach under the left end of the instrument panel to access and unsnap the rod end clip on the park brake release link and disengage the link from the back of the handle (Fig. 1). 5. Remove the three screws that secure the lower edge of the steering column opening cover to the lower instrument panel reinforcement. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 7374 6. Using a trim stick or another suitable wide flat-bladed tool, gently pry the upper edge of the steering column opening cover just below the cluster bezel on each side of the steering column away from the instrument panel far enough to disengage each of the snap clip retainers from their receptacles in the instrument panel base trim (Fig. 2). 7. Remove the steering column opening cover from the instrument panel. 8. Remove the two screws in the hooded area above the instrument cluster that secures the cluster bezel to the instrument panel base trim (Fig. 3). 9. Using a trim stick or another suitable wide flat-bladed tool, gently pry around the perimeter of the cluster bezel to disengage the snap clips from their receptacles in the instrument panel base trim. 10. Pull the right side of the cluster bezel away from the instrument panel far enough to access and disconnect the instrument panel wire harness connector for the headlamp switch from the switch connector receptacle. 11. Pull the left side of the cluster bezel away from the instrument panel far enough to access and disconnect the instrument panel wire harness connectors from the receptacles for the passenger airbag ON/OFF switch (if equipped), the rear window defogger switch (if equipped), the HVAC control, and the transfer case switch (if equipped). 12. Remove the cluster bezel from the instrument panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 08-032-00A > Dec > 00 > 4X4 Service Lamp - ON, 4X2 Vehicle > Page 7375 13. Remove the four screws that secure the HVAC control to the cluster bezel (Fig. 4). 14. Remove the HVAC control from the instrument panel. 15. Position the new HVAC control (see Parts Required section) in the cluster bezel and secure it with four screws. Tighten the screws to 2.2 Nm (17 i3 in. lbs.) 16. Position the cluster bezel to the instrument panel. 17. Pull the left side of the cluster bezel away from the instrument panel far enough to access and reconnect the instrument panel wire harness connectors to the receptacles for the passenger airbag on/off switch (if equipped), the rear window defogger switch (if equipped), the HVAC control, and the transfer case switch (if equipped). 18. Pull the right side of the cluster bezel away from the instrument panel far enough to access and reconnect the instrument panel wire harness connector for the headlamp switch to the switch connector receptacle. 19. Align the snap clips on the cluster bezel with the receptacles in the instrument panel base trim. 20. Using hand pressure, press firmly on the cluster bezel over each of the snap clip locations until each snap clip is fully engaged in their receptacle. 21. Install and tighten the two screws in the hooded area above the instrument cluster that secure the cluster bezel to the instrument panel base trim (Fig. 3). Tighten the screws to 2.2 Nm (20 in. lbs.). 22. Position the steering column opening cover to the instrument panel. 23. Align the snap clip retainers on the steering column opening cover with the receptacles in the instrument panel base trim. 24. Using hand pressure, press firmly on the steering column opening cover over the snap clip locations until each of the snap clips are fully engaged in their receptacle. 25. Install and tighten the three screws that secure the lower edge of the steering column opening cover to the instrument structural support. Tighten the screws to 2.2 Nm (20 in.lbs.). 26. Reach under the left end of the instrument panel to access and engage the park brake release link to the back of the handle. Then snap the rod end clip over the park brake release link to secure the connection. 27. Reconnect the battery negative cable. 28. On vehicles equipped with A/C, perform the A/C cool down test using the DRBIII(R). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Locations Fuel Gauge: Locations The fuel gauge is located in the lower right quadrant of the instrument cluster, below the oil pressure gauge. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Locations > Page 7379 Fuel Gauge: Description and Operation A fuel gauge is standard equipment on all instrument clusters. The fuel gauge is located in the lower right quadrant of the instrument cluster, below the oil pressure gauge. The fuel gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from E (or Empty) to F (or Full). An International Control and Display Symbol icon for "Fuel" is located on the cluster overlay in the center of the gauge directly above the hub of the gauge needle. An arrowhead pointed to the left side of the vehicle is imprinted on the cluster overlay next to the "Fuel" icon in the fuel gauge to provide the driver with a reminder as to the location of the fuel filler access. The fuel gauge graphics are white against a black field except for a single red graduation at the low end of the gauge scale, making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned ON, the white graphics appear blue-green and the red graphics appear red. The orange gauge needle is internally illuminated. Gauge illumination is provided by replaceable incandescent bulb and bulb holder units located on the instrument cluster electronic circuit board. The fuel gauge is serviced as a unit with the instrument cluster. The fuel gauge gives an indication to the vehicle operator of the level of fuel in the fuel tank. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The fuel gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Percent Tank Full Message - Each time the cluster receives a message from the PCM indicating the percent tank full, the cluster programming applies an algorithm to calculate the proper gauge needle position, then moves the gauge needle to the proper position on the gauge scale. The algorithm is used to dampen gauge needle movement against the negative effect that fuel sloshing within the fuel tank can have on accurate inputs from the fuel tank sending unit to the PCM. - Less Than 12.5 Percent Tank Full Message - Each time the cluster receives messages from the PCM indicating the percent tank full is 12.5 (one- eighth) or less for 10 consecutive seconds and the vehicle speed is zero, or for 60 consecutive seconds and the vehicle speed is greater than zero, the gauge needle is moved to the proper position on the gauge scale, the low fuel indicator is illuminated, and a single chime tone is sounded. The low fuel indicator remains illuminated until the cluster receives messages from the PCM indicating that the percent tank full is greater than 12.5 (one-eighth) for 10 consecutive seconds and the vehicle speed is zero, or for 60 consecutive seconds and the vehicle speed is greater than zero, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the low fuel indicator is cycled OFF and then on again by the appropriate percent tank full messages from the PCM. - Less Than Empty Percent Tank Full Message - Each time the cluster receives a message from the PCM indicating the percent tank full is less than empty, the gauge needle is moved to the far left (low) end of the gauge scale and the low fuel indicator is illuminated immediately. This message would indicate that the fuel tank sender input to the PCM is a short circuit. - More Than Full Percent Tank Full Message - Each time the cluster receives a message from the PCM indicating the percent tank full is more than full, the gauge needle is moved to the far left (low) end of the gauge scale and the low fuel indicator is illuminated immediately. This message would indicate that the fuel tank sender input to the PCM is an open circuit. - Message Failure - If the cluster fails to receive a percent tank full message, it will hold the gauge needle at the last indication until a new message is received, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM continually monitors the fuel tank sending unit, then sends the proper messages to the instrument cluster. For further diagnosis of the fuel gauge or the instrument cluster circuitry that controls the gauge, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the fuel tank sending unit, the PCM, the PCI data bus, or the message inputs to the instrument cluster that control the fuel gauge, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations Fuel Gauge Sender: Locations Fig. 7 Fuel Gauge Sending Unit Location - Typical Module The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The fuel pump module is located inside of fuel tank. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 7383 Fuel Gauge Sender: Description and Operation FUEL LEVEL SENDING UNIT / SENSOR The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation: A constant input voltage source of about 12 volts (battery voltage) is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 7384 Fuel Gauge Sender: Testing and Inspection The fuel gauge sending unit contains a variable resistor (track). As the float moves up or down, electrical resistance will change. Refer to Instrument Panel and Gauges for Fuel Gauge testing. To test the gauge sending unit only, it must be removed from vehicle. The unit is part of the fuel pump module. Refer to Fuel Pump Module Removal/installation for procedures. Measure the resistance across the sending unit terminals. With float in up position, resistance should be 20 ohms ± 6%. With float in down position, resistance should be 270 ohms ± 6%. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 7385 Fuel Gauge Sender: Service and Repair REMOVAL Fig. 7 Fuel Gauge Sending Unit Location - Typical Module The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module (Fig. 7). The fuel pump module is located inside of fuel tank. 1. Remove fuel tank. 2. Remove fuel pump module. 3. Unplug 4-way electrical connector (Fig. 7). 4. Disconnect 2 sending unit wires at 4-way connector. The locking collar of connector must be removed before wires can be released from connector. Note location of wires within 4-way connector. Fig. 8 Fuel Gauge Sending Unit Lock Tab/Tracks Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 7386 5. The sending unit is retained to pump module with a small lock tab and notch (Fig. 8). Carefully push lock tab to the side and away from notch while sliding sending unit downward on tracks for removal. Note wire routing while removing unit from module. INSTALLATION The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module (Fig. 7). The fuel pump module is located inside of fuel tank. 1. Position sending unit into tracks. Note wire routing. 2. Push unit on tracks until lock tab snaps into notch. 3. Connect 2 sending unit wires into 4-way connector and install locking collar. 4. Connect 4-way electrical connector to module. 5. Install fuel pump module. 6. Install fuel tank. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 7391 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Application and ID Instrument Panel Bulb: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Illumination .......................................................................................................................................... .............................................................. PC194 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Locations Low Fuel Lamp/Indicator: Locations The low fuel indicator is located in the Information Center area of the instrument cluster overlay, to the left of center. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Locations > Page 7398 Low Fuel Lamp/Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Low Fuel .............................................................................................................................................. .............................................................. PC194 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Locations > Page 7399 Low Fuel Lamp/Indicator: Description and Operation A low fuel indicator is standard equipment on all instrument clusters. The low fuel indicator is located in the Information Center area of the instrument cluster overlay, to the left of center. The low fuel indicator consists of a stenciled cutout of the International Control and Display Symbol icon for "Fuel" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber lens behind the cutout in the opaque layer of the overlay causes the icon to appear in amber through the translucent outer layer of the overlay when the indicator is illuminated from behind by a Light Emitting Diode (LED) soldered onto the instrument cluster electronic circuit board. The low fuel indicator is serviced as a unit with the instrument cluster. The low fuel indicator gives an indication to the vehicle operator when the level of fuel in the fuel tank becomes low. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The low fuel indicator Light Emitting Diode (LED) receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions; therefore, the LED will always be OFF when the ignition switch is in any position except ON or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the low fuel indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the indicator is illuminated for about two seconds as a bulb test. - Less Than 12.5 Percent Tank Full Message - Each time the cluster receives messages from the PCM indicating the percent tank full is 12.5 (one-eighth) or less for 10 consecutive seconds and the vehicle speed is zero, or for 60 consecutive seconds and the vehicle speed is greater than zero, the low fuel indicator is illuminated and a single chime tone is sounded. The low fuel indicator remains illuminated until the cluster receives messages from the PCM indicating that the percent tank full is greater than 12.5 (one-eighth) for 10 consecutive seconds and the vehicle speed is zero, or for 60 consecutive seconds and the vehicle speed is greater than zero, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the low fuel indicator is cycled OFF and then ON again by the appropriate percent tank full messages from the PCM. - Less Than Empty Percent Tank Full Message - Each time the cluster receives a message from the PCM indicating the percent tank full is less than empty, the low fuel indicator is illuminated immediately. This message would indicate that the fuel tank sender input to the PCM is a short circuit. - More Than Full Percent Tank Full Message - Each time the cluster receives a message from the PCM indicating the percent tank full is more than full, the low fuel indicator is illuminated immediately. This message would indicate that the fuel tank sender input to the PCM is an open circuit. - Actuator Test - Each time the cluster is put through the actuator test, the indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the fuel tank sending unit, then sends the proper messages to the instrument cluster. For further diagnosis of the low fuel indicator or the instrument cluster circuitry that controls the LED, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the fuel tank sending unit, the PCM, the PCI data bus, or the message inputs to the instrument cluster that control the low fuel indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Application and ID Maintenance Required Lamp/Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Maintenance Required ........................................................................................................................ ................................................................ PC194 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Locations Malfunction Indicator Lamp: Locations The MIL is located in the Information Center area of the instrument cluster overlay, to the left of center. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Locations > Page 7406 Malfunction Indicator Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Check Engine ...................................................................................................................................... ............................................................... PC194 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Locations > Page 7407 Malfunction Indicator Lamp: Description and Operation A Malfunction Indicator Lamp (MIL) is standard equipment on all instrument clusters. The MIL is located in the Information Center area of the instrument cluster overlay, to the left of center. The MIL consists of a stencilled cutout of the International Control and Display Symbol icon for "Engine" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber lens behind the cutout in the opaque layer of the overlay causes the icon to appear in amber through the translucent outer layer of the overlay when the indicator is illuminated from behind by a Light Emitting Diode (LED) soldered onto the instrument cluster electronic circuit board. The MIL is serviced as a unit with the instrument cluster. The Malfunction Indicator Lamp (MIL) gives an indication to the vehicle operator when the Powertrain Control Module (PCM) has recorded a Diagnostic Trouble Code (DTC) for an On-Board Diagnostics II (OBDII) emissions-related circuit or component malfunction. The MIL is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the PCM over the Programmable Communications Interface (PCI) data bus. The MIL Light Emitting Diode (LED) receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions; therefore, the LED will always be OFF when the ignition switch is in any position except ON or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the MIL for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the indicator is illuminated for about seven seconds as a bulb test. - PCM Lamp-ON Message - Each time the cluster receives a lamp-on message from the PCM, the indicator will be illuminated. The indicator can be flashed ON and OFF, or illuminated solid, as dictated by the PCM message. For some DTC's, if a problem does not recur, the PCM will send a lamp-off message automatically. Other DTC's may require that a fault be repaired and the PCM be reset before a lamp-OFF message will be sent. For more information on the PCM, and the DTC set and reset parameters, (Refer to EMISSIONS CONTROL - OPERATION). - Communication Error - If the cluster receives no lamp-on message from the PCM for twenty seconds, the MIL is illuminated by the instrument cluster to indicate a loss of bus communication. The indicator remains controlled and illuminated by the cluster until a valid lamp-ON message is received from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the indicator will be turned ON during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the fuel and emissions system circuits and sensors to decide whether the system is in good operating condition. The PCM then sends the proper lamp-ON or lamp-OFF messages to the instrument cluster. If the instrument cluster turns ON the MIL after the bulb test, it may indicate that a malfunction has occurred and that the fuel and emissions systems may require service. For proper diagnosis of the fuel and emissions systems, the PCM, the PCI data bus, or the message inputs to the instrument cluster that control the MIL, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Description and Operation Odometer: Description and Operation An odometer and trip odometer are standard equipment in all instrument clusters. The odometer and trip odometer information are displayed in a common electronic Vacuum-Fluorescent Display (VFD), which is visible through a small window cutout located in the left lower quadrant of the cluster overlay. However, the odometer and trip odometer information are not displayed simultaneously. The trip odometer reset switch on the instrument cluster circuit board toggles the display between odometer and trip odometer modes by depressing the odometer/ trip odometer switch knob that extends through the lower edge of the cluster lens, just right of the odometer VFD. When the trip odometer information is displayed, the word "TRIP" is also illuminated in a green color and at the same lighting level as the trip odometer information in the lower right corner of the VFD. Both the odometer and the trip odometer information is stored in the instrument cluster memory. The odometer can display values up to 499,999 kilometers (499,999 miles). The odometer latches at these values, and will not roll over to zero. The trip odometer can display values up to 999.9 kilometers (999.9 miles) before it rolls over to zero. The odometer display does not have a decimal point and will not show values less than a full unit (kilometer or mile), the trip odometer display does have a decimal point and will show tenths of a unit (kilometer or mile). The unit of measure (kilometers or miles) for the odometer and trip odometer display is not shown in the VFD. The unit of measure for the instrument cluster odometer/trip odometer is selected at the time that it is manufactured, and cannot be changed. During daylight hours (exterior lamps OFF) the VFD is illuminated at full brightness for clear visibility. At night (exterior lamps are ON) the VFD lighting level is adjusted with the other cluster illumination lamps using the panel lamps dimmer thumbwheel on the headlamp switch. However, a "Parade" mode position of the panel lamps dimmer thumbwheel allows the VFD to be illuminated at full brightness while the exterior lamps are turned ON during daylight hours. The VFD, the trip odometer switch, and the trip odometer switch button are serviced as a unit with the instrument cluster. The odometer and trip odometer give an indication to the vehicle operator of the distance the vehicle has traveled. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The odometer and trip odometer information is displayed by the instrument cluster Vacuum Fluorescent Display (VFD), and the VFD will not display odometer or trip odometer information after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the VFD and provides the following features: - Odometer/Trip Odometer Display Toggling - Actuating the trip odometer reset switch momentarily with the ignition switch in the ON position will toggle the VFD between the odometer and trip odometer display. Each time the ignition switch is turned to the ON position the VFD will automatically return to the mode (odometer or trip odometer) last displayed when the ignition switch was turned to the OFF position. - Trip Odometer Reset - When the trip odometer reset switch is pressed and held for longer than about two seconds, the trip odometer will be reset to 000.0 kilometers (miles). The VFD must be displaying the trip odometer information in order for the trip odometer information to be reset. - Message Failure - If the cluster fails to receive a distance message during normal operation, it will flash the odometer/trip odometer distance information ON and OFF repeatedly until a distance message is received, or until the ignition switch is turned to the OFF position, whichever occurs first. If the cluster does not receive a distance message within one second after the ignition switch is turned to the ON position, it will display the last distance message stored in the cluster memory. If the cluster is unable to display distance information due to an error internal to the cluster, the VFD display will be blank. - Actuator Test - Each time the cluster is put through the actuator test, the VFD will display all of its characters at once, then step through each character segment individually during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. The PCM continually monitors the vehicle speed sensor, then sends the proper distance messages to the instrument cluster. For further diagnosis of the odometer/trip odometer or the instrument cluster circuitry that controls these functions, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the vehicle speed sensor, the PCM, the PCI data bus, or the message inputs to the instrument cluster that control the odometer/trip odometer, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation Oil Change Reminder Lamp: Description and Operation This Vehicle does not come equipped with an OIL CHANGE REMINDER LAMP. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation > Page 7414 Oil Change Reminder Lamp: Service and Repair This Vehicle does not come equipped with an OIL CHANGE REMINDER LAMP. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Locations Oil Pressure Gauge: Locations The oil pressure gauge is located in the upper right quadrant of the instrument cluster, above the fuel gauge. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Locations > Page 7418 Oil Pressure Gauge: Description and Operation An oil pressure gauge is standard equipment on all instrument clusters. The oil pressure gauge is located in the upper right quadrant of the instrument cluster, above the fuel gauge. The oil pressure gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from "L" (or Low) to "H" (or High). An International Control and Display Symbol icon for "Engine Oil" is located on the cluster overlay, in the center of the gauge directly above the hub of the gauge needle. The oil pressure gauge graphics are white against a black field except for a single red graduation at the low end of the gauge scale, making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned ON, the white graphics appear blue-green and the red graphics appear red. The orange gauge needle is internally illuminated. Gauge illumination is provided by replaceable incandescent bulb and bulb holder units located on the instrument cluster electronic circuit board. The oil pressure gauge is serviced as a unit with the instrument cluster. The oil pressure gauge gives an indication to the vehicle operator of the engine oil pressure. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The oil pressure gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Oil Pressure Message - The instrument cluster circuitry restricts the oil pressure gauge needle operation in order to provide readings that are consistent with customer expectations. Each time the cluster receives a message from the PCM indicating the engine oil pressure is between about 6.9 kPa (1 psi) and 137.9 kPa (20 psi), the cluster holds the gauge needle at a point about 11 degrees above the low end of normal increment on the gauge scale. Each time the cluster receives a message from the PCM indicating the engine oil pressure is between about 517.1 kPa (75 psi) and 755 kPa (109.5 psi), the cluster holds the gauge needle at a point about 7.4 degrees below the high end of normal increment on the gauge scale. When the cluster receives messages from the PCM indicating the engine oil pressure is between about 137.9 kPa (20 psi) and 517.1 kPa (75 psi), the gauge needle is moved to the actual pressure position on the gauge scale. - Engine Oil Pressure Low Message - Each time the cluster receives a message from the PCM indicating the engine oil pressure is below about 6.9 kPa (1 psi), the gauge needle is moved to the L (Low) graduation at the far left end of the gauge scale, the check gauges indicator is illuminated, and a single chime tone is generated. The gauge needle remains at the low end of the scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM indicating that the engine oil pressure is above about 6.9 kPa (1 psi), or until the ignition switch is turned to the OFF position, whichever occurs first. The cluster will only turn the check gauges indicator lamp ON in response to an engine oil pressure low message if the engine speed message is greater than zero. - Engine Oil Pressure High Message - Each time the cluster receives a message from the PCM indicating the engine oil pressure is above about 755 kPa (109.5 psi), the gauge needle is moved to the H (High) graduation at the far right end of the gauge scale. The gauge needle remains at the high end of the scale until the cluster receives a message from the PCM indicating that the engine oil pressure is below about 755 kPa (109.5 psi), or until the ignition switch is turned to the OFF position, whichever occurs first. - Message Failure - If the cluster fails to receive an engine oil pressure message, it will hold the gauge needle at the last indication until a new message is received, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM continually monitors the engine oil pressure sensor to determine the engine oil pressure. The PCM then sends the proper engine oil pressure messages to the instrument cluster. For further diagnosis of the oil pressure gauge or the instrument cluster circuitry that controls the gauge, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). If the instrument cluster turns ON the check gauges indicator due to a low oil pressure gauge reading, it may indicate that the engine or the engine oiling system requires service. For proper diagnosis of the engine oil pressure sensor, the PCM, the PCI data bus, or the message inputs to the instrument cluster that control the oil pressure gauge, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Application and ID Oil Pressure Warning Lamp/Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Engine Oil Pressure ............................................................................................................................. ............................................................... PC194 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component Information > Locations Overdrive Indicator Lamp: Locations The Overdrive OFF Indicator (VFD) is part of the cluster electronic circuit board, and is visible through a cutout located in the lower right corner of the cluster overlay. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component Information > Locations > Page 7425 Overdrive Indicator Lamp: Description and Operation OVERDRIVE OFF INDICATOR An overdrive OFF indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional overdrive automatic transmission, this indicator is electronically disabled. The overdrive OFF indicator consists of the text "O/D OFF", which appears in the lower portion of the electronic gear selector indicator Vacuum Fluorescent Display (VFD). The VFD is part of the cluster electronic circuit board, and is visible through a cutout located in the lower right corner of the cluster overlay. The dark lens of the VFD prevents the indicator from being clearly visible when it is not illuminated. The text "O/D OFF" appears in an amber color and at the same lighting level as the gear selector indicator information when it is illuminated by the instrument cluster electronic circuit board. The overdrive OFF indicator is serviced as a unit with the VFD in the instrument cluster. The overdrive OFF indicator gives an indication to the vehicle operator when the OFF position of the overdrive OFF switch has been selected, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The overdrive OFF indicator receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions; therefore, the indicator will always be OFF when the ignition switch is in any position except ON or Start. The indicator only illuminates when it is switched to ground by the instrument cluster circuitry. The instrument cluster will turn ON the overdrive OFF indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the overdrive OFF indicator is illuminated for about two seconds as a bulb test. - Overdrive OFF Lamp-ON Message - Each time the cluster receives an overdrive OFF lamp-ON message from the PCM indicating that the OFF position of the overdrive OFF switch has been selected, the overdrive OFF indicator will be illuminated. The indicator remains illuminated until the cluster receives an overdrive OFF lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the overdrive OFF indicator will be turned ON, then OFF again during the VFD portion of the test to confirm the functionality of the VFD, and again during the bulb check portion of the test to confirm the functionality of the cluster control circuitry. The PCM continually monitors the overdrive OFF switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper overdrive OFF lamp-ON and lamp-OFF messages to the instrument cluster. For further diagnosis of the overdrive OFF indicator or the instrument cluster circuitry that controls the indicator, (Refer to INSTRUMENT/CLUSTER DIAGNOSIS AND TESTING). For proper diagnosis of the overdrive control system, the PCM, the PCI data bus, or the message inputs to the instrument cluster that control the overdrive OFF indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 BRAKE/PARK BRAKE INDICATOR A brake indicator is standard equipment on all instrument clusters. The brake indicator is located in the Information Center area of the instrument cluster; to the right of center. The brake indicator consists of a stenciled cutout of the word "BRAKE" and the International Control and Display Symbol icons for "Brake Failure" and "Parking Brake" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red lens behind the cutout in the opaque layer of the overlay causes the "BRAKE" text and the two icons to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by a Light Emitting Diode (LED) soldered onto the instrument cluster electronic circuit board. The brake indicator is serviced as a unit with the instrument cluster. The brake indicator gives an indication to the vehicle operator when the parking brake is applied, or when there are certain brake hydraulic system malfunctions. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming, and electronic messages received by the cluster from the Central Timer Module (CTM) and the Controller Antilock Brake (CAB) over the Programmable Communications Interface (PCI) data bus. The brake indicator Light Emitting Diode (LED) receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions; therefore, the LED will always be OFF when the ignition switch is in any position except ON or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the brake indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the brake indicator is illuminated by the instrument cluster for about four seconds as a bulb test. - Brake Lamp-ON Message - Each time the cluster receives a lamp-on message from the CTM or the CAB, the brake indicator will be illuminated. If the park brake is applied or not fully released, or if the pressures in the two halves of the split brake hydraulic system are not equal with the ignition switch in the ON position, the brake indicator is illuminated solid. The brake indicator will blink ON and OFF repeatedly when the park brake is applied or not fully released and the ignition switch is in the ON position if the automatic transmission is not in Park or Neutral. The indicator remains illuminated until the cluster receives lamp-OFF messages from both the CTM and the CAB, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the instrument cluster is put through the actuator test, the brake indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The park brake switch on the park brake pedal mechanism provides a hard wired ground input to the CTM circuitry through the park brake switch sense circuit whenever the park brake is applied or not fully released. The CTM then sends the proper lamp-ON or lamp-OFF messages to the instrument cluster. The brake pressure switch on the brake combination valve provides a hard wired ground input to the CAB circuitry through the brake pressure switch sense circuit whenever the pressures in the two halves of the split brake hydraulic system are unequal. The CAB then sends the proper lamp-ON or lamp-OFF messages to the instrument cluster. If the CAB sends a lamp-ON message after the bulb test, it indicates that the CAB has detected a brake hydraulic system malfunction and/or that the ABS system has become inoperative. The CAB will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. The park brake switch input to the CTM and the brake pressure switch input to the CAB can be diagnosed using conventional diagnostic tools and methods. For proper diagnosis of the antilock brake system, the CTM, the CAB, the PCI data bus, or the message inputs to the instrument cluster that control the brake indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Locations Audible Warning Device Control Module: Locations The Central Timer Module is located behind the left side kick panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device Control Module: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7435 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7436 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7437 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7438 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7439 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7440 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7441 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7442 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7443 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7444 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7445 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7446 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7447 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7448 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7449 Audible Warning Device Control Module: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7450 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7451 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7452 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7453 Audible Warning Device Control Module: Connector Views Central Timer Module C1 Central Timer Module C2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7454 Central Timer Module C3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7455 Audible Warning Device Control Module: Electrical Diagrams 8w-45-2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7456 8w-45-3 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7457 8w-45-4 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7458 8w-45-5 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7459 8w-45-6 (Base) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7460 8w-45-7 (Light Package) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7461 8w-45-8 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7462 8w-45-9 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7463 8w-45-10 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7464 8w-45-11 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7465 8w-45-12 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7466 8w-45-13 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7467 8w-45-14 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7468 8w-45-15 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams See: Diagrams/Electrical Diagrams Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 7469 Audible Warning Device Control Module: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 7470 Audible Warning Device Control Module: Description and Operation For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. See: Body and Frame/Body Control Systems/Central Timer Module CENTRAL TIMER MODULE The Durango (DN) utilizes a Central Timer Module (CTM). This system is available in a Base or Highline configuration. The CTM performs most of the typical functions a Body Control Module would perform. The Base and Highline CTM provides the following features: Battery Saver Functions For Exterior and Interior Lamps - Cargo Lamps - Chime Warning - Courtesy Lamps - Dome Lamps - Dome Defeat - Door Ajar Switch Status - Fog Lamps - Head Lamp Time Delay - Intermittent Wiper Controls - Low and High Beam Head Lamps - Optical Horn - Park Lamps Additional features of Highline CTM Central Locking (VTSS) - Door Lock Inhibit - Driver Door Unlock - Enhanced Accident Response - Power Door Locks - Remote Radio - Remote Keyless Entry - Vehicle Theft Alarm (VTSS) Fig. 1 Central Timer Module The Central Timer Module is located behind the left side kick panel. It contains 26-way, 16-way and 12-way connectors. The high-line Central Timer Module (CTM) can also control some features of the audio system when the vehicle is equipped with the optional RAZ radio receiver and remote radio switches. A high-line CTM is used on high-line versions of this vehicle. The CTM combines the functions of a chime/buzzer module, an intermittent wipe module, an illuminated entry module, a remote keyless entry module, and a vehicle theft security Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 7471 system module in a single unit. The high-line CTM also controls and integrates many of the additional electronic functions and features included on models with this option. The RAZ radio receiver with a remote radio switch option is one of the features that the CTM controls. The CTM is programmed to send switch status messages over the J185O data bus to control the volume, seek, and pre-set station advance functions of the RAZ radio receiver. The CTM monitors the status of the remote radio switches located on the steering wheel through a hard wired circuit. The CTM then sends the proper switch status messages to the radio receiver. The electronic circuitry within the radio receiver responds to the switch status messages it receives by adjusting the radio settings as requested. In addition, radio receivers connected to the J1850 data bus have several audio system functions that can be diagnosed using a DRB scan tool. Refer to the proper Diagnostic Procedures for more information on DRB testing of the audio systems. Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. Whichever version of the CTM the vehicle is equipped with, it is concealed behind the trim on the left cowl side inner panel below the instrument panel, where it is secured with three screws. The CTM is enclosed in a molded plastic housing with three integral external connector receptacles that connect it to the vehicle electrical system through one take out and connector of the body wire harness, and two take outs and connectors of the instrument panel wire harness. The base version of the CTM is used on base models of this vehicle. These base models are not equipped with the optional power lock system, the Remote Keyless Entry (RKE) system, the rear wiper system, the Vehicle Theft Security System (VTSS), or the remote radio controls. The high-line version of the CTM is used on high-line vehicles that are equipped with one or more of those options not found on base models. The CTM utilizes integrated circuitry and information carried on the Programmable Communications Interface (PCI) data bus network along with many hard wired inputs to monitor many sensor and switch inputs throughout the vehicle. In response to those inputs, the internal circuitry and programming of the CTM allow it to supply the vehicle occupants with audible and visual information, and to control and integrate many electronic functions and features of the vehicle through both hard wired outputs and the transmission of electronic message outputs to other electronic modules in the vehicle over the PCI data bus. The features that the CTM supports or controls include the following: Automatic Door Lock - The high-line CTM provides an automatic door lock feature (also known as rolling door locks). This is a programmable feature. - Battery Protection - The CTM provides a battery saver feature that performs timed load shedding whenever courtesy, reading, visor vanity, center console, glove box, or any exterior lamps are left on with the ignition switch in the OFF position. - Central Locking - The high-line CTM on vehicles equipped with the optional Vehicle Theft Security System (VTSS) includes a central locking/ unlocking feature. - Chimes - All versions of the CTM provide chime service and beep request service through an integral chime tone generator. - Door Lock Inhibit - The high-line CTM provides a power door lock inhibit feature. - Enhanced Accident Response - The high-line CTM provides an optional enhanced accident response feature. This is a programmable feature. - Exterior Light Features - The CTM provides control of park lamps, fog lamps, and headlamps. This includes support for optical horn (also known as flash-to-pass), headlamp time delay, daytime running lamps (DRL - Canada only), and battery saver features. - Interior Light Features - The CTM provides control of courtesy lamps, dome lamps, and the liftgate lamp. This includes support for a timed illuminated entry with fade-to-OFF, interior lighting delay, courtesy illumination defeat, and battery saver features. - Intermittent Wipe Control - The CTM provides control of the intermittent wipe delay, and wipe-after-wash features for the front wiper and washer system. The high-line CTM also provides these same features for the optional rear wiper and washer system. - Panic Mode - The high-line CTM provides support for the optional RKE system panic mode including horn chirp, headlamp flash, and park lamp flash features. - Power Lock Control - The high-line CTM provides the optional power lock system features, including support for the automatic door lock and door lock inhibit modes. - Programmable Features - The CTM provides support for certain programmable features. - Remote Keyless Entry - The high-line CTM provides the optional Remote Keyless Entry (RKE) system features, including support for the RKE Lock (with optional horn chirp and park lamps flash), Unlock (with optional park lamps flash, driver-door- only unlock, and unlock-all-doors), Panic, and illuminated entry modes, as well as the ability to be programmed to recognize up to four RKE transmitters. The RKE horn chirp, park lamps flash, driver- door-only unlock, and unlock-all-doors features are programmable. - Remote Radio Switch Interface - The high- line CTM monitors and transmits the status of the optional remote radio switches on the steering wheel. - Speed Sensitive Intermittent Wipe Control - The CTM provides a speed sensitive front intermittent wipe feature. - Vehicle Theft Security System - The high-line CTM provides control of the optional Vehicle Theft Security System (VTSS) features, including support for the central locking/unlocking mode and control of the Security indicator in the instrument cluster. Hard wired circuitry connects the CTM to the electrical system of the vehicle. These hard wired circuits are integral to several wire harnesses, which are routed throughout the vehicle and retained by many different methods. These circuits may be connected to each other, to the vehicle electrical system and to the CTM through the use of a combination of soldered splices, splice block connectors, and many different types of wire harness terminal connectors and insulators. All versions of the CTM for this model are serviced only as a complete unit. Many of the electronic features in the vehicle controlled or supported by the CTM are programmable using the DRB III scan tool. In addition, the CTM software is Flash compatible, which means it can be reprogrammed using Flash reprogramming procedures. However, if any of the CTM hardware components are damaged or faulty, the entire CTM unit must be replaced. The hard wired inputs or outputs of all CTM versions can be diagnosed using conventional diagnostic tools and methods; however, for diagnosis of the CTM or the PCI data bus, the use of a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 7472 The microprocessor-based Central Timer Module (CTM) monitors many hard wired switch and sensor inputs as well as those resources it shares with other electronic modules in the vehicle through its communication over the Programmable Communications Interface (PCI) data bus network. The internal programming and all of these inputs allow the CTM microprocessor to determine the tasks it needs to perform and their priorities, as well as both the standard and optional features that it should provide. The CTM programming then performs those tasks and provides those features through both PCI data bus communication with other electronic modules and through hard wired outputs through a number of driver circuits, relays, and actuators. These outputs allow the CTM the ability to control numerous accessory systems in the vehicle. The CTM operates on battery current received through two fuses in the Junction Block (JB) on two non-switched fused B(+) circuits, a fused ignition switch output (run-start) circuit, and a fused ignition switch output (run-acc) circuit. This arrangement allows the CTM to provide some features regardless of the ignition switch position, while other features will operate only with the ignition switch in the Accessory, ON, and/or Start positions. The CTM receives ground through its connector and take out of the instrument panel wire harness on three separate ground circuits. Two of these circuits are grounded through a take out of the instrument panel wire harness with an eyelet terminal connector that is secured by a nut to a ground stud on the left inner cowl side panel near the CTM, while the third circuit is grounded through a take out of the instrument panel wire harness with an eyelet terminal connector that is secured by a ground screw to the left side of the floor panel transmission tunnel near the Airbag Control Module (ACM). The CTM monitors its own internal circuitry as well as many of its input and output circuits, and will store a Diagnostic Trouble Code (DTC) in electronic memory for any failure it detects. These DTCs can be retrieved and diagnosed using a DRB III scan tool. Refer to the appropriate diagnostic information. Hard Wired Inputs The hard wired inputs to the CTM include the following: Courtesy lamp switch sense - Cylinder lock switch sense - high line with VTSS only - Driver door ajar switch sense - Driver door switch mux - high line with power locks only - Fog lamp switch sense - Front washer pump/motor control - Front wiper park switch sense - Fused B(+) (two circuits) - Fused ignition switch output (run-acc) - Fused ignition switch output (run-start) - Ground (three circuits) - Headlamp switch off sense - High beam switch output - Interior lamp defeat - Intermittent front wiper mode sense - Intermittent front wiper switch signal - Key-in ignition switch sense - Liftgate ajar switch sense - Low beam switch output - Park brake switch sense - Park lamp switch sense - Passenger door ajar switch sense - Passenger door switch mux - high line with power locks only - PCI bus circuit - Radio control mux - high-line with remote radio switches only - Washer switch sense - Wiper park switch sense - Wiper switch mode sense - Wiper switch mode signal Hard Wired Outputs The hard wired outputs of the CTM include the following: Courtesy lamp driver - Door lock relay output - high-line with power locks only - Door unlock relay output - high-line with power locks only - Driver door unlock relay output - high-line with power locks only - Fog lamp relay control - with fog lamps only - Front washer pump/motor control - Front wiper park switch sense - Front wiper relay control - Glove box lamp driver - High beam indicator driver - Horn relay control - high-line with power locks only Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 7473 - Interior lamp driver - Left high beam driver - Left low beam driver - Park lamp relay control - Rear wiper park switch sense - high line with rear wiper and washer system only - Rear wiper relay control - high line with rear wiper and washer system only - Right high beam driver - Right low beam driver - VTSS indicator driver - high-line with VTSS only Messaging The CTM uses the following messages received from other electronic modules over the PCI data bus: Airbag Deploy (ACM) - Beep request (CMTC) - Charging System Failure (PCM) - Chime request (EMIC) - Engine RPM (PCM) - OK to Arm VTSS (PCM) - Rear Washer Status (Heater-A/C Control) - Rear Wiper Status (Heater-A/C Control) - Security indicator request (SKIM) - System Voltage (PCM) - Valid/Invalid Key (SKIM) - Vehicle Distance (PCM) - Vehicle Speed (PCM) - Voltage Fault (PCM) The CTM provides the following messages to other electronic modules over the PCI data bus: Door Ajar Status (EMIC) - Liftgate Ajar Status (EMIC) - Park Brake Status (CAB, EMIC, TCM) - Radio Mode (Radio) - Radio Preset Scan (Radio) - Radio Seek Down (Radio) - Radio Seek Up (Radio) - Radio Volume Down (Radio) - Radio Volume Up (Radio) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Testing and Inspection > Audible Warning Device Control Module: Testing and Inspection "Low Line" Central Timer Module (Chime) Test For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. See: Body and Frame/Body Control Systems/Central Timer Module The hard wired inputs to and outputs from the Central Timer Module (CTM) may be diagnosed and tested using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the CTM. In order to obtain conclusive testing of the CTM, the Programmable Communications Interface (PCI) data bus network and all of the electronic modules that provide inputs to or receive outputs from the CTM must also be checked. The most reliable, efficient, and accurate means to diagnose the CTM, the PCI data bus network, and the electronic modules that provide inputs to or receive outputs from the CTM requires the use of a DRB III scan tool. Refer to the appropriate diagnostic information. The DRB III scan tool can provide confirmation that the PCI data bus network is functional, that all of the electronic modules are sending and receiving the proper messages over the PCI data bus, and that the CTM is receiving the proper hard wired inputs and responding with the proper hard wired outputs needed to perform its many functions. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: The following tests may not prove conclusive in the diagnosis of the Central Timer Module (CTM). The most reliable, efficient, and accurate means to diagnose the CTM requires the use of a DRB III scan tool. Refer to the appropriate diagnostic information. 1. Check the fused B(+) fuses (Fuse 3 - 20 ampere, and Fuse 12 - 20 ampere) in the Power Distribution Center (PDC). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fused B(+) fuses (Fuse 3 - 20 ampere, and Fuse 12 - 20 ampere) in the PDC. If OK, go to Step 3. If not OK, repair the open B(+) circuit between the PDC and the battery as required. 3. Disconnect and isolate the battery negative cable. Disconnect the instrument panel wire harness connector (Connector C3) for the CTM from the CTM connector receptacle. Reconnect the battery negative cable. Check for battery voltage at each of the two fused B(+) circuit cavities of the instrument panel wire harness connector (Connector C3) for the CTM. If OK, disconnect and isolate the battery negative cable, reconnect the instrument panel wire harness connector (Connector C3) for the CTM to the CTM connector receptacle, and go to Step 4. If not OK, repair the open fused B(+) circuit(s) between the CTM and the PDC as required. 4. Check the fused ignition switch output (run-start) fuse (Fuse 11 - 10 ampere) and the fused ignition switch output (run-acc) fuse (Fuse 5 - 20 ampere) in the Junction Block (JB). If OK, go to Step 5. If not OK, repair the shorted circuit or component as required and replace the faulty fuse(s). 5. Reconnect the battery negative cable. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run-start) fuse (Fuse 11 - 10 ampere) and the fused ignition switch output (run-acc) fuse (Fuse 5 20 ampere) in the JB. If OK, go to Step 6. If not OK, repair the open fused ignition switch output (run-start) circuit or fused ignition switch output (run-acc) circuit between the JB and the ignition switch as required. 6. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the instrument panel wire harness connector (Connector C1) for the CTM from the CTM connector receptacle. Reconnect the battery negative cable. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run-start) circuit cavity and the fused ignition switch output (run-acc) cavity of the instrument panel wire harness connector (Connector C1) for the CTM. If OK, go to Step 7. If not OK, repair the open fused ignition switch output (run-start) circuit or fused ignition switch output (run-acc) circuit between the CTM and the JB as required. 7. Turn the ignition switch to the OFF position. Check for continuity between each of the three ground circuits in the instrument panel wire harness connector (Connector C1) for the CTM and a good ground. In each case there should be continuity. If OK, use a DRB III scan tool to perform further diagnosis of the CTM. Refer to the appropriate diagnostic information. If not OK, repair the open ground circuit(s) to ground (G207 or G208) as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Testing and Inspection > Page 7476 Audible Warning Device Control Module: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: Before replacing a Central Timer Module (CTM), use a DRB III scan tool to retrieve the current settings for the CTM programmable features. Refer to the appropriate diagnostic information. These settings should be duplicated in the replacement CTM using the DRB III scan tool before returning the vehicle to service. 1. Disconnect and isolate the battery negative cable. 2. Remove the trim from the left cowl side inner panel. Fig. 2 Central Timer Module 3. Disconnect the two instrument panel wire harness connectors and one body wire harness connector from the CTM connector receptacles (Fig. 2). 4. Remove the three screws that secure the CTM to the left cowl side inner panel. 5. Remove the CTM from the left cowl side inner panel. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: Before replacing a Central Timer Module (CTM), use a DRB III scan tool to retrieve the current settings for the CTM programmable features. Refer to the appropriate diagnostic information. These settings should be duplicated in the replacement high-line/premium CTM using the DRB III scan tool before returning the vehicle to service. 1. Position the CTM onto the left cowl side inner panel (Fig. 2). 2. Install and tighten the three screws that secure the CTM to the left cowl side inner panel. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the two instrument panel wire harness connectors and one body wire harness connector to the CTM connector receptacles. 4. Reinstall the trim onto the left cowl side inner panel. 5. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Locations Speedometer Module: Locations The speedometer is located next to the tachometer, just to the right of center in the instrument cluster. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Locations Seat Belt Reminder Lamp: Locations The seatbelt indicator is located in the Information Center area of the instrument cluster, to the right of center. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Locations > Page 7483 Seat Belt Reminder Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Fasten Seat Belts ................................................................................................................................ ................................................................ PC194 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Locations > Page 7484 Seat Belt Reminder Lamp: Description and Operation A seatbelt indicator is standard equipment on all instrument clusters. The seatbelt indicator is located in the Information Center area of the instrument cluster, to the right of center. The seatbelt indicator consists of a stencilled cutout of the International Control and Display Symbol icon for "Seat Belt" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red lens behind the cutout in the opaque layer of the overlay causes the icon to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by a Light Emitting Diode (LED) soldered onto the instrument cluster electronic circuit board. The seatbelt indicator is serviced as a unit with the instrument cluster. The seatbelt indicator gives an indication to the vehicle operator of the status of the driver side front seatbelt. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and a hard wired input from the seatbelt switch in the driver side front seatbelt retractor through the seat belt indicator driver circuit. The seatbelt indicator Light Emitting Diode (LED) receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions; therefore, the indicator will always be OFF when the ignition switch is in any position except ON or Start. The LED only illuminates when it is switched to ground by the instrument cluster transistor. The instrument cluster will turn ON the seatbelt indicator for the following reasons: - Seatbelt Reminder Function - Each time the cluster receives a battery current input on the fused ignition switch output (run-start) circuit, the indicator will be illuminated as a seatbelt reminder for about seven seconds, or until the ignition switch is turned to the OFF position, whichever occurs first. This reminder function will occur regardless of the status of the seatbelt switch input to the cluster. - Driver Side Front Seatbelt Not Buckled - Following the seatbelt reminder function, each time the cluster detects an open circuit on the seat belt indicator driver circuit (seatbelt switch open - seatbelt unbuckled) with the ignition switch in the Start or ON positions, the indicator will be illuminated. The seatbelt indicator remains illuminated until the seat belt indicator driver input to the cluster is closed to ground (seatbelt switch closed - seatbelt buckled), or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The seatbelt switch input to the instrument cluster circuitry can be diagnosed using conventional diagnostic tools and methods. For further diagnosis of the seatbelt indicator or the instrument cluster circuitry that controls the LED, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions Door Switch: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7490 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7491 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7492 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7493 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7494 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7495 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7496 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7497 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7498 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7499 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7500 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7501 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7502 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7503 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7504 Door Switch: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7505 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7506 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7507 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7508 Door Switch: Connector Views Driver Door Power Lock Motor/Ajar Switch Left Rear Door Power Lock Motor/Ajar Switch Passenger Door Power Lock Motor/Ajar Switch Right Rear Door Power Lock Motor/Ajar Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7509 Door Ajar Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 7510 Door Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 7511 Door Switch: Description and Operation DOOR AJAR SWITCH The door ajar switches are integral to the door latches on each door. The switches close a path to ground for the Central Timer Module (CTM) when a door is opened, and open the ground path when a door is closed. The door ajar switches cannot be repaired and, if faulty or damaged, the door latch unit must be replaced. The door ajar switches close a path to ground for the Central Timer Module (CTM) when a door is opened, and opens the ground path when a door is closed. The passenger side front door and both rear door ajar switches are connected in a parallel-series circuit between ground and the CTM, while the driver side front door ajar switch is connected in series between ground and the CTM to provide a unique input. The CTM reads the switch status through an internal pull-up, then sends the proper switch status messages to other electronic modules over the Programmable Communications Interface (PCI) data bus network. The door ajar switches can be diagnosed using conventional diagnostic tools and methods. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 7512 Door Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Disconnect the door latch pigtail wire connector from the door wire harness connector. Check for continuity between the ground circuit cavity in the door wire harness connector and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the open ground circuit to ground as required. 2. Check for continuity between the ground circuit cavity and the driver or passenger door ajar switch sense circuit cavity in the door latch pigtail wire connector. There should be continuity with the door opened, and no continuity with the door closed. If OK, go to Step 3. If not OK, replace the faulty door latch unit. 3. Disconnect the body wire harness connector (Connector C2) for the Central Timer Module (CTM) from the CTM connector receptacle. Check for continuity between the driver or passenger door ajar switch sense circuit cavity of the body wire harness connector (Connector C2) and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, repair the shorted driver or passenger door ajar switch sense circuit between the door latch and the CTM as required. 4. Check for continuity between the driver or passenger door ajar switch sense circuit cavities of the body wire harness connector (Connector C2) and the door wire harness connector for the door latch. There should be continuity. If OK, use a DRB III scan tool to diagnose the CTM. Refer to the appropriate diagnostic procedures. If not OK, repair the open driver or passenger door ajar switch sense circuit between the door latch and the CTM as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations Fuel Gauge Sender: Locations Fig. 7 Fuel Gauge Sending Unit Location - Typical Module The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The fuel pump module is located inside of fuel tank. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 7516 Fuel Gauge Sender: Description and Operation FUEL LEVEL SENDING UNIT / SENSOR The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation: A constant input voltage source of about 12 volts (battery voltage) is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 7517 Fuel Gauge Sender: Testing and Inspection The fuel gauge sending unit contains a variable resistor (track). As the float moves up or down, electrical resistance will change. Refer to Instrument Panel and Gauges for Fuel Gauge testing. To test the gauge sending unit only, it must be removed from vehicle. The unit is part of the fuel pump module. Refer to Fuel Pump Module Removal/installation for procedures. Measure the resistance across the sending unit terminals. With float in up position, resistance should be 20 ohms ± 6%. With float in down position, resistance should be 270 ohms ± 6%. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 7518 Fuel Gauge Sender: Service and Repair REMOVAL Fig. 7 Fuel Gauge Sending Unit Location - Typical Module The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module (Fig. 7). The fuel pump module is located inside of fuel tank. 1. Remove fuel tank. 2. Remove fuel pump module. 3. Unplug 4-way electrical connector (Fig. 7). 4. Disconnect 2 sending unit wires at 4-way connector. The locking collar of connector must be removed before wires can be released from connector. Note location of wires within 4-way connector. Fig. 8 Fuel Gauge Sending Unit Lock Tab/Tracks Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 7519 5. The sending unit is retained to pump module with a small lock tab and notch (Fig. 8). Carefully push lock tab to the side and away from notch while sliding sending unit downward on tracks for removal. Note wire routing while removing unit from module. INSTALLATION The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module (Fig. 7). The fuel pump module is located inside of fuel tank. 1. Position sending unit into tracks. Note wire routing. 2. Push unit on tracks until lock tab snaps into notch. 3. Connect 2 sending unit wires into 4-way connector and install locking collar. 4. Connect 4-way electrical connector to module. 5. Install fuel pump module. 6. Install fuel tank. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Service and Repair Shift Indicator: Service and Repair GEARSHIFT INDICATOR REMOVAL The following service procedures apply only to the mechanical gear selector indicator. The electronic gear selector indicator is integral to the instrument cluster and can only be serviced by replacement of the instrument cluster unit. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument cluster from the instrument panel. Fig. 13 3. Remove the two screws that secure the gear selector indicator mechanism to the back of the instrument cluster housing (Fig. 13). 4. Remove the gear selector indicator mechanism from the back of the instrument cluster housing. 5. Remove the steering column opening cover from the instrument panel. Fig. 14 6. Disengage the loop end of the gear selector indicator cable from the lever on the left side of the steering column (Fig. 14). 7. Squeeze the sides of the plastic adjuster and bracket unit to disengage the tabs that secure it to the sides of the steering column window. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Service and Repair > Page 7523 8. Remove the gear selector indicator mechanism and cable unit from the instrument panel. INSTALLATION The following service procedures apply only to the mechanical gear selector indicator. The electronic gear selector indicator is integral to the instrument cluster and can only be serviced by replacement of the instrument cluster unit. 1. Position the gear selector indicator mechanism and cable unit to the instrument panel. 2. Squeeze the sides of the plastic adjuster and bracket unit and engage the tabs that secure it with the sides of the steering column window. 3. Engage the loop end of the gear selector indicator cable onto the lever on the left side of the steering column (Fig. 14). 4. Position the gear selector indicator mechanism onto the back of the instrument cluster housing. 5. Install and tighten the two screws that secure the gear selector indicator mechanism to the back of the instrument cluster housing. Tighten the screws to 2.2 N.m (20 in. lbs.). 6. Install the instrument cluster onto the instrument panel. 7. Check the gear selector indicator for proper calibration. If adjustment is needed, 8. Install the steering column opening cover onto the instrument panel. 9. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation Speedometer Head: Description and Operation SPEEDOMETER A speedometer is standard equipment on all instrument clusters. The speedometer is located next to the tachometer, just to the right of center in the instrument cluster. The speedometer consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 210 degree primary scale on the gauge dial face that reads left-to-right either from 0 to 120 mph, or from 0 to 200 kph, depending upon the market for which the vehicle is manufactured. Each version also has a secondary inner scale on the gauge dial face that provides the equivalent opposite units from the primary scale. Text appearing on the cluster overlay just above the hub of the speedometer needle abbreviates the unit of measure for the primary scale in all upper case letters (i.e.: MPH or KPH), followed by the unit of measure for the secondary scale in all lower case letters (i.e.: mph or kph). The speedometer graphics are white (primary scale) and red (secondary scale) against a black field, making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned ON, the white graphics appear blue-green and the red graphics appear red. The orange gauge needle is internally illuminated. Gauge illumination is provided by replaceable incandescent bulb and bulb holder units located on the instrument cluster electronic circuit board. The speedometer is serviced as a unit with the instrument cluster. The speedometer gives an indication to the vehicle operator of the vehicle road speed. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The speedometer is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Message Failure - If the cluster fails to receive a speedometer message, it will hold the gauge needle at the last indication for about four seconds, or until the ignition switch is turned to the OFF position, whichever occurs first. If a new speedometer message is not received after about four seconds, the gauge needle will return to the far left (low) end of the scale. - Actuator Test - Each time the cluster is put through the actuator test, the gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM continually monitors the vehicle speed sensor to determine the vehicle road speed, then sends the proper vehicle speed messages to the instrument cluster. For further diagnosis of the speedometer or the instrument cluster circuitry that controls the gauge, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the vehicle speed sensor, the PCM, the PCI data bus, or the message inputs to the instrument cluster that control the speedometer, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component Information > Locations Speedometer Module: Locations The speedometer is located next to the tachometer, just to the right of center in the instrument cluster. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Locations Tachometer: Locations The tachometer is located to the left of the speedometer, just to the left of center in the instrument cluster. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Locations > Page 7533 Tachometer: Description and Operation A tachometer is standard equipment on all instrument clusters. The tachometer is located to the left of the speedometer, just to the left of center in the instrument cluster. The tachometer consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 210 degree scale on the gauge dial face that reads left-to-right from 0 to 7. The text "RPM X 1000" imprinted on the cluster overlay directly above the hub of the tachometer needle identifies that each number on the tachometer scale is to be multiplied by 1000 rpm. The tachometer graphics are white against a black field, making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned ON, the white graphics appear blue-green. The orange gauge needle is internally illuminated. Gauge illumination is provided by replaceable incandescent bulb and bulb holder units located on the instrument cluster electronic circuit board. The tachometer is serviced as a unit with the instrument cluster. The tachometer gives an indication to the vehicle operator of the engine speed. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The tachometer is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Message Failure - If the cluster fails to receive an engine speed message, it will hold the gauge needle at the last indication for about four seconds, or until the ignition switch is turned to the OFF position, whichever occurs first. If a new engine speed message is not received after about four seconds, the gauge needle will return to the far left (low) end of the scale. - Actuator Test - Each time the cluster is put through the actuator test, the gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM continually monitors the crankshaft position sensor to determine the engine speed, then sends the proper engine speed messages to the instrument cluster. For further diagnosis of the tachometer or the instrument cluster circuitry that controls the gauge, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the crankshaft position sensor, the PCM, the PCI data bus, or the message inputs to the instrument cluster that control the tachometer, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Locations Temperature Gauge: Locations The engine coolant temperature gauge is located in the lower left quadrant of the instrument cluster, below the voltage gauge. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Locations > Page 7537 Temperature Gauge: Description and Operation An engine coolant temperature gauge is standard equipment on all instrument clusters. The engine coolant temperature gauge is located in the lower left quadrant of the instrument cluster, below the voltage gauge. The engine coolant temperature gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from "C" (or Cold) to "H" (or Hot) for all engines. An International Control and Display Symbol icon for "Engine Coolant Temperature" is located on the cluster overlay, in the center of the gauge directly above the hub of the gauge needle. The engine coolant temperature gauge graphics are white against a black field except for a single red graduation at the high end of the gauge scale, making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned ON, the white graphics appear blue-green and the red graphics appear red. The orange gauge needle is internally illuminated. Gauge illumination is provided by replaceable incandescent bulb and bulb holder units located on the instrument cluster electronic circuit board. The engine coolant temperature gauge is serviced as a unit with the instrument cluster. The engine coolant temperature gauge gives an indication to the vehicle operator of the engine coolant temperature. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The engine coolant temperature gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Temperature Message - Each time the cluster receives a message from the PCM indicating the engine coolant temperature is between the low end of normal [about 54 °C (130 °F) and the high end of normal [about 129 °C (264 °F), the gauge needle is moved to the actual temperature position on the gauge scale. - Engine Temperature Low Message - Each time the cluster receives a message from the PCM indicating the engine coolant temperature is below the low end of normal [about 54 °C (130 °F)], the gauge needle is held at the "C" increment at the far left end of the gauge scale. The gauge needle remains at the far left end of the scale until the cluster receives a message from the PCM indicating that the engine temperature is above about 54 °C (130 °F), or until the ignition switch is turned to the OFF position, whichever occurs first. - Engine Temperature High Message - Each time the cluster receives a message from the PCM indicating the engine coolant temperature is above about 122 °C (251 °F), the gauge needle is moved to the appropriate position on the gauge scale, the check gauges indicator is illuminated, and a single chime tone is sounded. The check gauges indicator remains illuminated until the cluster receives a message from the PCM indicating that the engine temperature is below about 119 °C (246 °F), or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the check gauges indicator is cycled OFF and then on again by the appropriate engine temperature messages from the PCM. - Message Failure - If the cluster fails to receive an engine temperature message, it will hold the gauge needle at the last indication until a new message is received, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM continually monitors the engine coolant temperature sensor to determine the engine operating temperature. The PCM then sends the proper engine coolant temperature messages to the instrument cluster. For further diagnosis of the engine coolant temperature gauge or the instrument cluster circuitry that controls the gauge, (Refer to INSTRUMENT CLUSTER DIAGNOSIS AND TESTING). If the instrument cluster turns ON the check gauges indicator due to a high engine temperature gauge reading, it may indicate that the engine or the engine cooling system requires service. For proper diagnosis of the engine coolant temperature sensor, the PCM, the PCI data bus, or the message inputs to the instrument cluster that control the engine coolant temperature gauge, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Warning Indicator - A/T > Component Information > Locations Temperature Warning Indicator - A/T: Locations The transmission over-temperature indicator is located in the Information Center area of the instrument cluster, to the left of center. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Warning Indicator - A/T > Component Information > Locations > Page 7541 Temperature Warning Indicator - A/T: Description and Operation A transmission over-temperature indicator lamp is standard equipment on all instrument clusters. The transmission over-temperature indicator is located in the Information Center area of the instrument cluster, to the left of center. The transmission over-temperature indicator consists of a stencilled cutout of the words "TRANS TEMP" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red lens behind the cutout in the opaque layer of the overlay causes the "TRANS TEMP" text to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by a Light Emitting Diode (LED) soldered onto the instrument cluster electronic circuit board. The transmission overtemperature indicator is serviced as a unit with the instrument cluster. The transmission over-temperature indicator gives an indication to the vehicle operator when the trans- mission fluid temperature is excessive, which may lead to accelerated transmission component wear or failure. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The transmission over-temperature indicator Light Emitting Diode (LED) receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions; therefore, the LED will always be OFF when the ignition switch is in any position except ON or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the transmission over-temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the transmission over-temperature indicator is illuminated for about two seconds as a bulb test. - Trans Over-Temp Lamp-ON Message - Each time the cluster receives a trans over-temp lamp-ON message from the PCM indicating that the transmission fluid temperature is 135 °C (275 °F) or higher, the indicator will be illuminated and a single chime tone is sounded. The lamp remains illuminated until the cluster receives a trans over-temp lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the transmission over-temperature indicator is cycled OFF and then on again by the appropriate trans over-temp messages from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition, then sends the proper messages to the instrument cluster. If the instrument cluster turns ON the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission and/or the transmission cooling system are being overloaded or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). For proper diagnosis of the transmission temperature sensor, the PCM, the PCI data bus, or the message inputs to the instrument cluster that control the transmission over-temperature indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Application and ID Temperature Warning Lamp/Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Temperature Indicator ......................................................................................................................... ............................................................... PC194 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Description and Operation Transmission Shift Position Indicator Lamp: Description and Operation GEAR SELECTOR INDICATOR An electronic automatic transmission gear selector indicator is standard factory-installed equipment on this model. The gear selector indicator information is displayed in a Vacuum-Fluorescent Display (VFD), which is visible through a small window cutout located in the lower right quadrant of the cluster overlay. The gear selector indicator displays the following characters from left to right: 'P," "R," "N," "D," "2," and "1." Respectively, these characters represent the park, reverse, neutral, drive, second gear, and first gear positions of the transmission gear selector lever on the steering column. The VFD illuminates a rectangular box around the character that represents the currently selected lever position. During daylight hours (exterior lamps OFF) the gear selector indicator VFD is illuminated at full brightness for clear visibility. At night (exterior lamps are ON) the VFD lighting level is adjusted with the other cluster illumination lamps using the panel lamps dimmer thumbwheel on the headlamp switch. However, a "Parade" mode position of the panel lamps dimmer thumbwheel allows the VFD to be illuminated at full brightness while the exterior lamps are turned ON during daylight hours. The gear selector indicator VFD is serviced as a unit with the instrument cluster. The electronic gear selector indicator gives an indication to the vehicle operator of the transmission gear that has been selected with the automatic transmission gear selector lever. This gauge is controlled by the instrument cluster circuit board based upon cluster programming. The cluster circuitry automatically configures itself for the proper automatic transmission model based upon the hard wired transmission range sensor mux circuit input to the cluster. Each time the cluster is disconnected from battery current for more than about five minutes, it must configure itself again for the automatic transmission model that is in the vehicle when it is reconnected to battery current. The gear selector indicator information is displayed by a dedicated Vacuum Fluorescent Display (VFD) on the instrument cluster electronic circuit board, and the VFD will not display the gear selector indicator information after the ignition switch is turned to the OFF position. The instrument cluster circuitry configures the gear selector indicator VFD based upon the following inputs from the transmission range sensor: - Open Circuit - If the transmission range sensor mux circuit is open, the cluster circuitry controls the gear selector indicator display based upon electronic messages received from the electronic Transmission Control Module (TCM) over the Programmable Communications Interface (PCI) data bus. If the input is open circuit and no electronic messages are received from the TCM within two seconds, the instrument cluster circuitry will cycle the indicated gear selector position from P to R, to N, to D to 2 repeatedly and continuously until the condition is resolved or until the ignition switch is turned to the OFF position, whichever occurs first. - Resolved Circuit - If the transmission range sensor mux circuit is resolved, the cluster circuitry controls the gear selector indicator display based upon the resistance value of the hard wired input from the transmission range sensor. If the cluster has configured itself for the transmission range sensor input and detects a short to ground in the transmission range sensor mux input, the cluster will indicate all positions in the VFD; or, if this input is open circuit, the cluster will blink all positions in the VFD. The VFD display for the short-to-ground and open circuit conditions will continue until the condition is resolved or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the VFD will display all of its characters at once, then step through each character segment individually during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. On models with a TCM, the TCM continually monitors the transmission range sensor, then sends the proper gear selector indicator messages to the instrument cluster. On models without a TCM, the instrument cluster continually monitors the hard wired transmission range sensor multiplexed input. For further diagnosis of the gear selector indicator or the instrument cluster circuitry that controls this function, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). On models without a TCM, for further diagnosis of the transmission range sensor, (Refer to TRANSAXLE/AUTOMATIC - RE/TRANSMISSION RANGE SENSOR - DIAGNOSIS AND TESTING) or (Refer to TRANSAXLE/AUTOMATIC - RE/TRANSMISSION RANGE SENSOR DIAGNOSIS AND TESTING). On models with a TCM, for proper diagnosis of the transmission range sensor, the TCM, the PCI data bus, or the message inputs to the instrument cluster that control the gear selector indicator, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Locations Volt Meter Gauge: Locations The voltage gauge is located in the upper left quadrant of the instrument cluster, above the temperature gauge. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Locations > Page 7551 Volt Meter Gauge: Description and Operation A voltage gauge is standard equipment on all instrument clusters. The voltage gauge is located in the upper left quadrant of the instrument cluster, above the temperature gauge. The voltage gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to- right from "L" (or Low) to "H" (or High). An International Control and Display Symbol icon for "Battery Charging Condition" is located on the cluster overlay, in the center of the gauge directly above the hub of the gauge needle. The voltage gauge graphics are white against a black field except for a single red graduation at each end of the gauge scale, making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned ON, the white graphics appear blue-green and the red graphics appear red. The orange gauge needle is internally illuminated. Gauge illumination is provided by replaceable incandescent bulb and bulb holder units located on the instrument cluster electronic circuit board. The voltage gauge is serviced as a unit with the instrument cluster. The voltage gauge gives an indication to the vehicle operator of the electrical system voltage. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The voltage gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Charge Fail Message - Each time the cluster receives a message from the PCM indicating a charge fail condition (system voltage is 10.8 volts or lower), the gauge needle is moved to the "L" graduation on the gauge scale and the check gauges indicator is illuminated. The gauge needle remains on the "L" graduation and the check gauges indicator remains illuminated until the cluster receives a message from the PCM indicating there is no charge fail condition (system voltage is 10.9 volts or higher, but lower than 16.7 volts), or until the ignition switch is turned to the OFF position, whichever occurs first. - Voltage High Message - Each time the cluster receives a message from the PCM indicating a voltage high condition (system voltage is 16.7 volts or higher), the gauge needle is moved to the "H" graduation on the gauge scale and the check gauges indicator is illuminated. The gauge needle remains on the "H" graduation and the check gauges indicator remains illuminated until the cluster receives a message from the PCM indicating there is no voltage high condition (system voltage is 16.6 volts or lower, but higher than 10.9 volts), or until the ignition switch is turned to the OFF position, whichever occurs first. - Message Failure - If the cluster fails to receive a system voltage message, it will hold the gauge needle at the last indication until a new message is received, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM continually monitors the system voltage to control the generator output. The PCM then sends the proper system voltage messages to the instrument cluster. For further diagnosis of the voltage gauge or the instrument cluster circuitry that controls the gauge, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). If the instrument cluster turns ON the check gauges indicator due to a charge fail or voltage high condition, it may indicate that the charging system requires service. For proper diagnosis of the charging system, the PCI data bus, or the message inputs to the instrument cluster that control the voltage gauge, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Application and ID Backup Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Table Back-up ............................................................................................................................................... .................................................................. 3057 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Application and ID Brake Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Table Tail, Brake, Turn Signal and Side Marker ............................................................................................................................................................ 3057 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations > Page 7563 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7564 Brake Light Switch: Diagrams Brake Lamp Switch Brake Lamp Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7565 Brake Light Switch: Description and Operation The plunger type brake lamp switch is mounted on a bracket attached to the brake pedal support. CAUTION: The switch can only be adjusted during initial installation. If the switch is not adjusted properly a new switch must be installed. The primary function of the switch is to turn ON the brake lamps during braking. The switch is also used to send signals to components that must know when the brakes are applied, such as the Powertrain Control Module (PCM), which uses the signal to cancel speed control. The CAB uses the brake switch signal to monitor brake pedal application. When the switch contacts open (brakes applied), the CAB receives the brake applied signal. The CAB then monitors the RWAL system to anticipate the need for an RWAL stop. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7566 Brake Light Switch: Testing and Inspection Fig.1 Brake Lamp Switch Terminal Identification The brake lamp switch can be tested with an ohm-meter. The ohmmeter is used to check continuity between the pin terminals. Switch Circuit Identification - Terminals 1 and 2: brake lamp circuit - Terminals 3 and 4: RWAL/ABS module and Powertrain Control Module (PCM) circuit - Terminals 5 and 6: speed control circuit Switch Continuity Test NOTE: Disconnect switch harness before testing switch continuity. With switch plunger extended, attach test leads to pins 1 and 2. Replace switch if meter indicates no continuity. With switch plunger retracted, attach test leads to pins 3 and 4. Replace switch if meter indicates no continuity. With switch plunger retracted, attach test leads to pins 5 and 6. Replace switch if meter indicates no continuity. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7567 Brake Light Switch: Service and Repair Fig.2 Brake Lamp Switch & Bracket REMOVAL 1. Disconnect switch harness. 2. Press and hold brake pedal in applied position. 3. Rotate switch counterclockwise about 300 to align switch lock tab with notch in bracket. 4. Pull switch rearward out of mounting bracket and release brake pedal. INSTALLATION 1. Press and hold brake pedal down. 2. Align tab on new switch with notch in switch bracket. Then insert switch in bracket and turn it clockwise about 30 ° to lock it in place. 3. Connect harness wires to switch. 4. Release brake pedal. 5. Move the release lever on the switch to engage the switch plunger. The switch is now adjusted and can not be adjusted again. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Service and Repair > Liftgate/Cargo Lamp Bulb Replacement Cargo Lamp: Service and Repair Liftgate/Cargo Lamp Bulb Replacement REMOVAL 1. Remove liftgate/cargo lamp from liftgate. 2. Using a small flat blade, pry lamp lens from lamp. 3. Remove bulb from lamp. INSTALLATION 1. Install in bulb in lamp. 2. Install lamp lens on lamp. 3. Install liftgate/cargo lamp in liftgate. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Service and Repair > Liftgate/Cargo Lamp Bulb Replacement > Page 7572 Cargo Lamp: Service and Repair Liftgate/Cargo Lamp Unit Replacement REMOVAL 1. Using a small flatblade, carefully pry the outward edge of the liftgate/cargo lamp from trim panel. 2. Release the locking tab on the lamp harness connector and disconnect the harness connector from the lamp. Fig. 8 Liftgate/Cargo Lamp 3. Separate the lamp from the liftgate. INSTALLATION 1. Connect the harness connector to the lamp. 2. Position the lamp in the liftgate and press inward to secure. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams Center High Mounted Stop Lamp No.2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Page 7576 Center Mounted Brake Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Table Center High Mounted Stop lamp ......................................................................................................... .................................................................... 922 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Service and Repair > Center High Mounted Stop Lamp (CHMSL) Replacement Center Mounted Brake Lamp: Service and Repair Center High Mounted Stop Lamp (CHMSL) Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove CHMSL from liftgate. 3. Turn bulb socket 1/4 turn counterclockwise. 4. Separate socket from lamp. 5. Grasp bulb and pull from socket. INSTALLATION 1. Position bulb in socket and press into place. 2. Position socket in lamp. 3. Turn bulb socket 1/4 turn clockwise. 4. Install CHMSL. 5. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Service and Repair > Center High Mounted Stop Lamp (CHMSL) Replacement > Page 7579 Center Mounted Brake Lamp: Service and Repair Center High Mounted Stop Lamp Unit (CHMSL) Replacement Fig. 3 Center High Mounted Stop Lamp REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove liftgate trim panel. 3. Remove CHMSL lamp mounting screws. 4. Remove CHMSL lamp. 5. Turn bulb sockets 1/4 turn counterclockwise. 6. Separate socket from lamp. INSTALLATION 1. Position socket in lamp. 2. Turn bulb sockets 1/4 turn clockwise. 3. Position CHMSL lamp in place and install mounting screws. 4. Install liftgate trim panel. 5. Connect battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Application and ID Ash Tray Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Ash Receiver ....................................................................................................................................... .................................................................... 161 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams Center Console Lamp Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams Glove Box Lamp And Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Page 7590 Glove Box Lamp: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Page 7591 Glove Box Lamp: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Open the glove box. 3. Reach through the glove box opening and behind the glove box opening upper reinforcement in the instrument panel to access and depress the retaining latches on the top and bottom of the glove box lamp and switch housing. Fig. 3 Glove Box Lamp And Switch Remove/Install 4. While holding the retaining latches depressed, push the glove box lamp and switch out through the mounting hole in the instrument panel glove box opening upper reinforcement. 5. Pull the glove box lamp and switch out from the mounting hole far enough to access the wire harness connector. 6. Disconnect the instrument panel wire harness connector from the glove box lamp and switch connector receptacle. 7. Remove the glove box lamp and switch from the instrument panel. INSTALLATION 1. Position the glove box lamp and switch to the instrument panel. 2. Reconnect the instrument panel wire harness connector to the glove box lamp and switch connector receptacle. 3. Feed the instrument panel wire harness back into the glove box lamp and switch mounting hole in the glove box opening upper reinforcement. 4. Align the glove box lamp and switch housing with the mounting hole in the instrument panel glove box opening upper reinforcement. 5. Push the glove box lamp and switch into the mounting hole in the instrument panel glove box opening upper reinforcement until the retaining latches are fully engaged. 6. Close the glove box. 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp Switch > Component Information > Diagrams Glove Box Lamp And Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp Switch > Component Information > Diagrams > Page 7595 Glove Box Lamp Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp Switch > Component Information > Diagrams > Page 7596 Glove Box Lamp Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Open the glove box. 3. Reach through the glove box opening and behind the glove box opening upper reinforcement in the instrument panel to access and depress the retaining latches on the top and bottom of the glove box lamp and switch housing. Fig. 3 Glove Box Lamp And Switch Remove/Install 4. While holding the retaining latches depressed, push the glove box lamp and switch out through the mounting hole in the instrument panel glove box opening upper reinforcement. 5. Pull the glove box lamp and switch out from the mounting hole far enough to access the wire harness connector. 6. Disconnect the instrument panel wire harness connector from the glove box lamp and switch connector receptacle. 7. Remove the glove box lamp and switch from the instrument panel. INSTALLATION 1. Position the glove box lamp and switch to the instrument panel. 2. Reconnect the instrument panel wire harness connector to the glove box lamp and switch connector receptacle. 3. Feed the instrument panel wire harness back into the glove box lamp and switch mounting hole in the glove box opening upper reinforcement. 4. Align the glove box lamp and switch housing with the mounting hole in the instrument panel glove box opening upper reinforcement. 5. Push the glove box lamp and switch into the mounting hole in the instrument panel glove box opening upper reinforcement until the retaining latches are fully engaged. 6. Close the glove box. 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Description and Operation Daytime Running Lamp: Description and Operation Fog lamps Canada vehicles use daytime running lamps. Check wiring circuit from fog lamps DRL. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair > Dome Lamp Bulb Replacement Dome Lamp Bulb: Service and Repair Dome Lamp Bulb Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a small flat blade, pry the left side (driver's side) of the lamp lens downward. 3. Pull bulb from lamp. INSTALLATION 1. Install bulb in lamp. 2. Position lens on lamp and snap into place. 3. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair > Dome Lamp Bulb Replacement > Page 7605 Dome Lamp Bulb: Service and Repair 2nd Seat Dome/Reading Lamp Bulb Replacement REMOVAL Fig. 4 Lamp Lens 1. Using a small flat blade, pry the center rearward edge of the dome/reading lamp lens downward from lamp. Fig. 7 Dome/Reading Lamp Bulb 2. Pull bulb from socket. INSTALLATION 1. Position bulb in lamp. 2. Push the lamp lens up into the lamp to secure. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions Door Switch: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7610 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7611 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7612 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7613 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7614 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7615 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7616 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7617 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7618 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7619 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7620 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7621 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7622 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7623 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7624 Door Switch: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7625 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7626 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7627 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7628 Door Switch: Connector Views Driver Door Power Lock Motor/Ajar Switch Left Rear Door Power Lock Motor/Ajar Switch Passenger Door Power Lock Motor/Ajar Switch Right Rear Door Power Lock Motor/Ajar Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7629 Door Ajar Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Page 7630 Door Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Page 7631 Door Switch: Description and Operation DOOR AJAR SWITCH The door ajar switches are integral to the door latches on each door. The switches close a path to ground for the Central Timer Module (CTM) when a door is opened, and open the ground path when a door is closed. The door ajar switches cannot be repaired and, if faulty or damaged, the door latch unit must be replaced. The door ajar switches close a path to ground for the Central Timer Module (CTM) when a door is opened, and opens the ground path when a door is closed. The passenger side front door and both rear door ajar switches are connected in a parallel-series circuit between ground and the CTM, while the driver side front door ajar switch is connected in series between ground and the CTM to provide a unique input. The CTM reads the switch status through an internal pull-up, then sends the proper switch status messages to other electronic modules over the Programmable Communications Interface (PCI) data bus network. The door ajar switches can be diagnosed using conventional diagnostic tools and methods. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Page 7632 Door Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Disconnect the door latch pigtail wire connector from the door wire harness connector. Check for continuity between the ground circuit cavity in the door wire harness connector and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the open ground circuit to ground as required. 2. Check for continuity between the ground circuit cavity and the driver or passenger door ajar switch sense circuit cavity in the door latch pigtail wire connector. There should be continuity with the door opened, and no continuity with the door closed. If OK, go to Step 3. If not OK, replace the faulty door latch unit. 3. Disconnect the body wire harness connector (Connector C2) for the Central Timer Module (CTM) from the CTM connector receptacle. Check for continuity between the driver or passenger door ajar switch sense circuit cavity of the body wire harness connector (Connector C2) and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, repair the shorted driver or passenger door ajar switch sense circuit between the door latch and the CTM as required. 4. Check for continuity between the driver or passenger door ajar switch sense circuit cavities of the body wire harness connector (Connector C2) and the door wire harness connector for the door latch. There should be continuity. If OK, use a DRB III scan tool to diagnose the CTM. Refer to the appropriate diagnostic procedures. If not OK, repair the open driver or passenger door ajar switch sense circuit between the door latch and the CTM as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Power Distribution Center Fog Lamp Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 7637 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 7638 Fog/Driving Lamp Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 7639 Fog Lamp Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations Hazard Warning Flasher: Locations The electronic combination flasher is installed in a dedicated connector of the instrument panel wire harness located under the instrument panel outboard of the steering column opening. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 7644 Hazard Warning Flasher: Diagrams Combination Flasher Combination Flasher Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 7645 Hazard Warning Flasher: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 7646 Hazard Warning Flasher: Description and Operation Fig. 4 Combination Flasher COMBINATION FLASHER The combination flasher is located in a dedicated connector on a take out of the instrument panel wire harness, located under the instrument panel just outboard of the instrument panel steering column opening. The combination flasher is a smart relay that functions as both the turn signal system and the hazard warning system flasher. The combination flasher has fourteen blade-type terminals that connect it to the vehicle electrical system through fourteen matching cavities in the instrument panel wire harness connector; however, only ten of the combination flasher terminals are used in this application. The combination flasher contains active electronic Integrated Circuitry (IC) elements. This flasher is designed to handle the current flow requirements of the factory-installed lighting. If supplemental lighting is added to the turn signal lamp circuits, such as when towing a trailer with lights, the combination flasher will automatically try to compensate to keep the flash rate the same. The combination flasher cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. The combination flasher has fourteen blade-type terminals, but only ten are used in this application. These ten terminals are intended for the following inputs and outputs: fused B(+), fused ignition switch output, right turn signal sense, left turn signal sense, hazard flasher signal, brake lamp switch output, and two outputs each for the right and left turn signal circuits. Constant battery voltage is supplied to the flasher so that it can perform the hazard warning function, and ignition switched battery voltage is supplied for the turn signal function. The Integrated Circuit (IC) within the combination flasher contains the logic that controls the flasher operation and the flash rate. The IC receives separate sense ground inputs from the multi-function switch for the hazard flasher, right turn signal, and left turn signal. A special design feature of the combination flasher allows it to "sense" that a turn signal circuit or bulb is not operating, and provide the driver an indication of the condition by flashing the remaining bulbs in the affected circuit at a higher rate (120 flashes-per-minute or higher). Conventional flashers either continue flashing at their typical rate (heavy-duty type), or discontinue flashing the affected circuit entirely (standard-duty type). Because of the active electronic elements within the combination flasher, it cannot be tested with conventional automotive electrical test equipment. If the combination flasher is believed to be faulty, test the turn signal and hazard warning system. Then replace the combination flasher with a known good unit to confirm system operation. (Refer to TURN SIGNAL & HAZARD WARNING SYSTEM DIAGNOSIS AND TESTING). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 7647 Hazard Warning Flasher: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Fig. 5 Combination Flasher 2. Reach under the outboard side of the steering column opening in the instrument panel to access the instrument panel wire harness connector for the combination flasher located on a mounting tab on the back of the instrument panel armature. 3. Grasp the combination flasher and connector firmly and pull them toward the dash panel to disengage the connector from the mounting tab on the instrument panel armature. 4. Remove the combination flasher from the instrument panel wire harness connector. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the combination flasher to the instrument panel wire harness connector. 2. Align the combination flasher terminals with the terminal cavities in the instrument panel wire harness connector. 3. Using hand pressure, push in firmly on the combination flasher until the terminals are fully seated in the terminal cavities in the instrument panel wire harness connector. 4. Align the slot in the combination flasher connector with the mounting tab on the instrument panel armature. 5. Using hand pressure, push the combination flasher connector firmly onto the mounting tab until it is fully engaged in the slot. 6. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams Multi-Function Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 7651 Hazard Warning Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 7652 Hazard Warning Switch: Description and Operation Fig.14 Multi-Function Switch MULTI-FUNCTION SWITCH The multi-function switch is secured with two screws to the multi-function switch mounting housing on the left side of the steering column, just below the steering wheel. The only visible parts of the multi-function switch are the control stalk that extends through a dedicated opening in the left side of the upper steering column shrouds, and the hazard warning switch push button that protrudes through an opening in the upper steering column shroud on the top of the steering column. The remainder of the switch, its mounting provisions, and its electrical connections are all concealed beneath the steering column shrouds. The multi-function switch control stalk has both nomenclature and International Control and Display Symbol graphics applied to it, which identify its many functions. An International Control and Display Symbol icon for "Hazard Warning" is applied to the top of the hazard warning switch push button. The switch housing and its controls are constructed of molded black plastic. A single connector receptacle connects the switch to the vehicle electrical system through a take out and connector of the instrument panel wire harness. The multi-function switch supports the following functions and features: - Continuous Wipe Modes - The control knob of the multi-function switch provides two continuous wipe switch positions, low speed or high speed. - Hazard Warning Control - The internal circuitry and hardware of the multi-function switch provide detent switching for activation and deactivation of the hazard warning system. - Headlamp Beam Selection - The internal circuitry and hardware of the multi-function switch provide detent switching for selection of the headlamp high or low beams. - Headlamp Optical Horn - The internal circuitry and hardware of the multi-function switch includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Intermittent Wipe Mode - The control knob of the multi-function switch provides an intermittent wipe mode with multiple delay interval positions. - Turn Signal Control - The internal circuitry and hardware of the multi-function switch provide both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signals. - Washer Mode - The control knob of the multi- function switch provides washer system operation when the knob is depressed towards the steering column. The multi-function switch cannot be adjusted or repaired. If any function of the switch is faulty, or if the switch is damaged, the entire switch unit must be replaced. The multi-function switch uses conventionally switched outputs and a variable resistor to control the many functions and features it provides using hard wired circuitry. The switch is grounded at all times through a single wire take out with an eyelet terminal connector of the instrument panel wire harness that is secured by a nut to a ground stud located on the left cowl side inner panel, near the left instrument panel end bracket. When the ignition switch is in the Accessory or ON positions, battery current from a fuse in the Junction Block (JB) is provided through a fused ignition switch output (run acc) circuit. Following are descriptions of how the multi-function switch operates to control the many functions and features it provides: Continuous Wipe Modes - When the control knob of the multi-function switch is rotated to the High or Low positions, the circuitry within the Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 7653 switch provides a battery current output directly to the high or low speed brush of the wiper motor. When the control knob is in the OFF position, the circuitry within the switch connects the output of the wiper motor park switch to the low speed brush of the wiper motor. - Hazard Warning Control - The hazard warning push button is pushed down to unlatch the switch and activate the hazard warning system, and pushed down again to latch the switch and turn the system OFF. When the hazard warning switch is latched (hazard warning OFF), the push button will be in a lowered position on the top of the steering column shroud; and, when the hazard warning switch is unlatched (hazard warning ON), the push button will be in a raised position. The multi-function switch hazard warning circuitry provides a signal to the hazard warning sense of the combination flasher to activate or deactivate the flasher output to the hazard warning lamps. - Headlamp Beam Selection - The multi-function switch control stalk is pulled towards the steering wheel past a detent, then released to actuate the headlamp beam selection switch. Each time the control stalk is actuated in this manner, the opposite headlamp mode from what is currently selected will be activated. The internal circuitry of the headlamp beam selection switch directs a ground signal output from the headlamp switch to the appropriate low beam or high beam sense of the Central Timer Module (CTM). The CTM then controls a hard wired output to activate the selected headlamp beams. - Headlamp Optical Horn - The left multi-function switch control stalk is pulled towards the steering wheel to just before a detent, to momentarily activate the headlamp high beams. The high beams will remain illuminated until the control stalk is released. The internal circuitry of the headlamp beam selection switch provides a momentary ground path to the CTM high beam sense. - Intermittent Wipe Mode - When the multi-function switch control knob is rotated to the Delay position, the circuitry within the switch provides a battery current signal to the Central Timer Module (CTM). If the Delay mode is selected, the control knob can then be rotated to multiple minor detent positions, which actuates a variable resistor within the switch and provides a hard wired output to the CTM that signals the desired delay interval for the intermittent wiper feature. - Turn Signal Control - The multi-function switch control stalk actuates the turn signal switch. When the control stalk is moved in the upward direction, the right turn signal circuitry is activated; and, when the control stalk is moved in the downward direction, the left turn signal circuitry is activated. The multi-function switch turn signal circuitry provides a signal to the right or left turn signal sense of the combination flasher to activate or deactivate the flasher output to the proper turn signal lamps. The turn signal switch has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that provides turn signals only until the multi-function switch control stalk is released. When the control stalk is moved to a turn signal switch detent position, the cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clock-spring mechanism rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. In other words, if the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. - Washer Mode - Pushing the control knob on the end of the multi-function switch control stalk towards the steering column provides a battery current output through the momentary single pole, single throw washer switch circuitry to provide a washer signal input to the CTM. The CTM then provides a battery current output to operate the washer pump/motor. If the wipers are not operating when the washer switch is actuated, the CTM will operate the wiper motor for as long as the washer switch is depressed plus about three additional wipe cycles. If the wipers are operating in the intermittent mode when the washer switch is actuated, the CTM will operate the wiper motor at a fixed low speed for as long as the washer switch is depressed plus about three additional wipe cycles before the wipers return to the selected intermittent wipe interval. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations The headlamp switch is located in the instrument panel, outboard of the steering column. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 7658 Headlamp Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 7659 Headlamp Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 7660 Headlamp Switch: Description and Operation The headlamp switch is located in the instrument panel, outboard of the steering column. It closes a path to ground for the Central Timer Module (CTM) when the park or head lamps are ON and the driver door ajar switch is closed (driver door is open). The headlamp switch opens the ground path when the headlamp switch is turned OFF. The ground path is also opened when the driver door ajar switch is open (driver door is closed). This switch also contains a rheostat for controlling the illumination level of the instrument cluster lamps. The headlamp switch cannot be repaired and, if faulty or damaged, it must be replaced. The headlamp switch has an OFF position, a parking lamp position, and a headlamp ON position. High beams are controlled by the multifunction switch on the steering column. The headlamp switch cannot be repaired. It must be replaced. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 7661 Headlamp Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the headlamp switch. (Refer to HEADLAMP SWITCH - REMOVAL). Headlamp Switch Continuity Table Fig. 14 Headlamp Switch 2. Using an ohmmeter, test for continuity between the terminals of the switch as shown in the Headlamp Switch Continuity table. 3. If test results are not obtained as shown in the Headlamp Switch Continuity table, replace the headlamp switch. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 7662 Headlamp Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel from the instrument panel. 3. Disconnect the wire harness connector from the headlamp switch. 4. Remove the headlamp switch from the cluster bezel. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the headlamp switch to the cluster bezel. 2. Install and tighten the screws that secure the headlamp switch. Tighten the screws to 2.2 Nm (20 in. lbs.). 3. Reconnect the wire harness to the headlamp switch. 4. Install the cluster bezel onto the instrument panel. 5. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Locations Hi-Beam Indicator Lamp: Locations The high beam indicator is located near the upper edge of the instrument cluster overlay, between the tachometer and the speedometer. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Locations > Page 7666 Hi-Beam Indicator Lamp: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Locations > Page 7667 Hi-Beam Indicator Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application High Beam ........................................................................................................................................... .............................................................. PC194 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Locations > Page 7668 Hi-Beam Indicator Lamp: Description and Operation A high beam indicator is standard equipment on all instrument clusters. The high beam indicator is located near the upper edge of the instrument cluster overlay, between the tachometer and the speedometer. The high beam indicator consists of a stenciled cutout of the International Control and Display Symbol icon for "High Beam" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A blue lens behind the cutout in the opaque layer of the overlay causes the icon to appear in blue when it is illuminated from behind by a replaceable incandescent bulb and bulb holder unit located on the instrument cluster electronic circuit board. The high beam indicator is serviced as a unit with the instrument cluster. The high beam indicator gives an indication to the vehicle operator when the headlamp high beams are illuminated. This indicator is hard wired on the instrument cluster electronic circuit board, and is controlled by the Central Timer Module (CTM) through the high beam indicator driver circuit input to the cluster based upon a control signal to the CTM from the headlamp beam select switch. The headlamp beam select switch is integral to the multi-function switch on the left side of the steering column. The high beam indicator bulb receives battery current on the instrument cluster electronic circuit board through a fused B(+) circuit at all times; therefore, the indicator remains operational regardless of the ignition switch position. The indicator only illuminates when it is provided with a path to ground by the CTM. The high beam indicator can be diagnosed using conventional diagnostic tools and methods. For proper diagnosis of the CTM and the inputs to the CTM that control the high beam indicator driver circuit, a DRB III scan tool is required. Refer to the appropriate diagnostic information. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Locations > Page 7669 Hi-Beam Indicator Lamp: Testing and Inspection The diagnosis found here addresses an inoperative headlamp high beam indicator condition. If the problem being diagnosed is related to inoperative headlamp high beams, be certain to repair the headlamp system before attempting to diagnose or repair the high beam indicator. If no headlamp system problems are found, the following procedure will help locate a short or open in the high beam indicator driver circuit. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Indicator Does Not Illuminate With High Beams Selected 1. Check the fused B(+) fuse (Fuse 1 - 15 ampere) in the Junction Block (JB). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fused B(+) fuse (Fuse 1 - 15 ampere) in the JB. If OK, go to Step 3. If not OK, repair the open fused B(+) circuit between the JB and the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Remove the instrument cluster from the instrument panel. Reconnect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the instrument panel wire harness connector (Connector C1) for the instrument cluster. If OK, go to Step 4. If not OK, repair the open fused B(+) circuit between the instrument cluster and the JB as required. 4. Disconnect and isolate the battery negative cable. Disconnect the instrument panel wire harness connector (Connector C1) for the Central Timer Module (CTM) from the CTM connector receptacle. Check for continuity between the high beam indicator driver circuit cavities of the instrument panel wire harness connector (Connector C1) for the CTM and the instrument panel wire harness connector (Connector C1) for the instrument cluster. There should be continuity. If OK, go to Step 5. If not OK, repair the open high beam indicator driver circuit between the instrument cluster and the CTM as required. 5. Reinstall the instrument cluster onto the instrument panel. Reconnect the battery negative cable. Install a jumper wire between the high beam indicator driver circuit cavity of the instrument panel wire harness connector (Connector C1) for the CTM and a good ground. The indicator should illuminate. If OK, diagnose the CTM and its inputs using a DRB III scan tool. Refer to the appropriate diagnostic procedures. If not OK, replace the faulty high beam indicator bulb and bulb holder unit. Indicator Stays Illuminated With High Beams Not Selected 1. Disconnect and isolate the battery negative cable. Disconnect the instrument panel wire harness connector (Connector C1) for the Central Timer Module (CTM) from the CTM connector receptacle. Check for continuity between the high beam indicator driver circuit cavity of the instrument panel wire harness connector (Connector C1) for the CTM and a good ground. There should be no continuity. If OK, diagnose the CTM and its inputs using a DRB III scan tool. Refer to the appropriate diagnostic procedures. If not OK, repair the shorted high beam indicator driver circuit between the CTM and the instrument cluster as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations Horn Relay is located in the Junction Block (JB). Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 7674 Horn Relay: Diagrams Junction Block (Front View) Horn Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 7675 Horn Relay: Service Precautions WARNING: - ON VEHICLES EQUIPPED WITH AIRBAGS, Refer TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 7676 Horn Relay: Description and Operation The horn relay is a electromechanical device that switches battery current to the horn when the horn switch grounds the relay coil. The horn relay is located in the Junction Block (JB), on the left end of the instrument panel in the passenger compartment. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the JB until further diagnosis is completed. See the fuse and relay layout label affixed to the inside surface of the fuse access panel for horn relay identification and location. The horn relay is a International Standards Organization (ISO) micro-relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The ISO micro-relay terminal functions are the same as a conventional ISO relay. However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay. The horn relay cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When the electromagnetic coil is energized, it draws the movable contact away from the normally closed fixed contact, and holds it against the other (normally open) fixed contact. When the electromagnetic coil is de-energized, spring pressure returns the movable contact to the normally closed position. The resistor or diode is connected in parallel with the electromagnetic coil in the relay, and helps to dissipate voltage spikes that are produced when the coil is de-energized. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 7677 Horn Relay: Testing and Inspection Fig.2 Horn Relay The horn relay is located in the Junction Block (JB) on the left end of the instrument panel in the passenger compartment of the vehicle. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the JB until further diagnosis is completed. See the fuse and relay layout label affixed to the inside surface of the fuse access panel for horn relay identification and location. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, Refer TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the horn relay from the JB. (Refer to HORN RELAY - REMOVAL) for the procedures. 2. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 4. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, perform the Relay Circuit Test that follows. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair the open circuit to the fuse in the PDC as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. This terminal supplies battery voltage to the horn(s). There should be continuity between the cavity for relay terminal 87 and the horn relay output circuit cavity of each horn wire harness connector at all times. If OK, go to Step 4. If not OK, repair the open circuit to the horn(s) as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay. It is connected to battery voltage and should be hot at all times. Check for battery voltage at the cavity for relay terminal 86. If OK, go to Step 5. If not OK, repair the open circuit to the fuse in the PDC as required. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. It is grounded through the horn switch when the horn switch is depressed. On vehicles equipped with the Remote Keyless Entry (RKE) system, the horn relay coil ground terminal can also be grounded by the Central Timer Module (CTM) in response to certain inputs related to the RKE system or the Vehicle Theft Security System. Check for continuity to ground at the cavity for relay terminal 85. There should be continuity with the horn switch depressed, and no continuity with the horn switch released. If not OK, (Refer to HORN SWITCH DIAGNOSIS AND TESTING). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 7678 Horn Relay: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the fuse access panel by inserting a finger in the finger recess molded into the panel and then pulling the panel sharply away from the left outboard end of the instrument panel. 3. See the fuse and relay layout label affixed to the inside of the fuse access panel for horn relay identification and location. 4. Grasp the horn relay firmly and pull it straight out from the JB. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. See the fuse and relay layout label affixed to the inside of the fuse access panel for the proper horn relay location. 2. Position the horn relay in the proper receptacle in the JB. 3. Align the horn relay terminals with the terminal cavities in the JB receptacle. 4. Push in firmly on the horn relay until the terminals are fully seated in the terminal cavities in the JB receptacle. 5. Insert the tabs on the forward edge of the fuse access panel in the notches on the forward edge of the instrument panel fuse access panel opening. 6. Press the rear edge of the fuse access panel in toward the instrument panel until the panel snaps back into place. 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Service Precautions Horn Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Service Precautions > Page 7682 Horn Switch: Description and Operation Fig. 3 Driver Side Airbag Module Trim Cover And Horn Switch A center-blow, normally open, resistive membrane-type horn switch is secured with heat stakes to the back side of the driver side airbag module trim cover in the center of the steering wheel . The switch consists of two plastic membranes, one that is flat and one that is slightly convex. These two membranes are secured to each other around the perimeter. Inside the switch, the centers of the facing surfaces of these membranes each has a grid made with an electrically conductive material applied to it. One of the grids is connected to a circuit that provides it with continuity to ground at all times. The grid of the other membrane is connected to the horn relay control circuit. The steering wheel and steering column must be properly grounded in order for the horn switch to function properly. The horn switch is only serviced as a part of the driver side airbag module trim cover. If the horn switch is damaged or faulty, or if the driver side airbag is deployed, the driver side airbag module trim cover and horn switch must be replaced as a unit. When the center area of the driver side airbag trim cover is depressed, the electrically conductive grids on the facing surfaces of the horn switch membranes contact each other, closing the switch circuit. The completed horn switch circuit provides a ground for the control coil side of the horn relay, which activates the relay. When the horn switch is released, the resistive tension of the convex membrane separates the two electrically conductive grids and opens the switch circuit. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Service Precautions > Page 7683 Horn Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Remove the steering column opening cover from the instrument panel. 2. Check for continuity between the metal steering column jacket and a good ground. There should be continuity. If OK, go to Step 3. 3. Remove the driver side airbag module from the steering wheel. Disconnect the horn switch wire harness connectors from the driver side airbag module. 4. Remove the horn relay from the Junction Block (JB). Check for continuity between the steering column half of the horn switch feed wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted horn relay control circuit to the horn relay in the JB as required. 5. Check for continuity between the steering column half of the horn switch feed wire harness connector and the horn relay control circuit cavity for the horn relay in the JB. There should be continuity. If OK, go to Step 6. If not OK, repair the open horn relay control circuit to the horn relay in the JB as required. 6. Check for continuity between the horn switch feed wire and the horn switch ground wire on the driver side airbag module. There should be no continuity. If OK, go to Step 7. If not OK, replace the faulty horn switch. 7. Depress the center of the driver side airbag module trim cover and check for continuity between the horn switch feed wire and the horn switch ground wire on the driver side airbag module. There should now be continuity. If not OK, replace the faulty horn switch. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Application and ID Key Cylinder Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Ignition Key .......................................................................................................................................... .................................................................... 53 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams License Lamp Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Page 7690 License Plate Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Table License Plate ....................................................................................................................................... .................................................................... 168 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Service and Repair > License Plate Lamp Replacement License Plate Lamp: Service and Repair License Plate Lamp Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove license plate lamp from rear bumper. Fig. 15 License Plate Lamp Bulb 3. Remove bulb socket from lamp. 4. Pull bulb from socket. INSTALLATION 1. Push bulb in socket. 2. Install bulb socket in lamp. 3. Install license plate lamp in rear bumper. 4. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Service and Repair > License Plate Lamp Replacement > Page 7693 License Plate Lamp: Service and Repair License Plate Lamp Unit Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove screws attaching license plate lamp to rear bumper. 3. Remove bulb socket from lamp. 4. Separate lamp from bumper. INSTALLATION 1. Install bulb socket in lamp. 2. Position lamp at bumper. 3. Install screws attaching license plate lamp to rear bumper. 4. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and Repair > Overhead Console Reading Lamp Bulb Replacement Map Light Bulb: Service and Repair Overhead Console Reading Lamp Bulb Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Starting in the center, use a small flat blade to carefully pry the lens from the housing. 3. Disengage lamp lens from overhead console. 4. Pull bulb from lamp. INSTALLATION 1. Position bulb in lamp. 2. Position lamp lens on overhead console. 3. Carefully press lamp lens onto pivots. 4. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and Repair > Overhead Console Reading Lamp Bulb Replacement > Page 7699 Map Light Bulb: Service and Repair 2nd Seat Dome/Reading Lamp Bulb Replacement REMOVAL Fig. 4 Lamp Lens 1. Using a small flat blade, pry the center rearward edge of the dome/reading lamp lens downward from lamp. Fig. 7 Dome/Reading Lamp Bulb 2. Pull bulb from socket. INSTALLATION 1. Position bulb in lamp. 2. Push the lamp lens up into the lamp to secure. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair Marker Lamp Bulb: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove park and turn signal lamp. Fig. 10 Headlamp Bulb 3. Remove side marker lamp socket from back of lamp. 4. Pull side marker lamp bulb from socket. INSTALLATION 1. Install side marker lamp bulb in socket. 2. Install side marker lamp socket into back of lamp. 3. Install park/turn signal lamp. 4. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Park Lamp Relay is located in the Junction Block (JB). Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 7708 Parking Lamp Relay: Diagrams Junction Block (Front View) Park Lamp Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Light Bulb > Component Information > Service and Repair Parking Light Bulb: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove park and turn signal lamp. Fig. 18 Park And Turn Signal Lamp Bulb 3. Rotate bulb socket 1/4 turn counterclockwise and pull turn signal lamp socket from back of lamp. 4. Pull park and turn signal lamp bulb from socket. INSTALLATION 1. Install park and turn signal lamp bulb in socket. 2. Install park and turn signal lamp socket into back of lamp. 3. Install park/turn signal lamp. 4. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Power Distribution Center Fog Lamp Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 7716 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 7717 Fog/Driving Lamp Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 7718 Fog Lamp Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Horn Relay is located in the Junction Block (JB). Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 7722 Horn Relay: Diagrams Junction Block (Front View) Horn Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 7723 Horn Relay: Service Precautions WARNING: - ON VEHICLES EQUIPPED WITH AIRBAGS, Refer TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 7724 Horn Relay: Description and Operation The horn relay is a electromechanical device that switches battery current to the horn when the horn switch grounds the relay coil. The horn relay is located in the Junction Block (JB), on the left end of the instrument panel in the passenger compartment. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the JB until further diagnosis is completed. See the fuse and relay layout label affixed to the inside surface of the fuse access panel for horn relay identification and location. The horn relay is a International Standards Organization (ISO) micro-relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The ISO micro-relay terminal functions are the same as a conventional ISO relay. However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay. The horn relay cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When the electromagnetic coil is energized, it draws the movable contact away from the normally closed fixed contact, and holds it against the other (normally open) fixed contact. When the electromagnetic coil is de-energized, spring pressure returns the movable contact to the normally closed position. The resistor or diode is connected in parallel with the electromagnetic coil in the relay, and helps to dissipate voltage spikes that are produced when the coil is de-energized. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 7725 Horn Relay: Testing and Inspection Fig.2 Horn Relay The horn relay is located in the Junction Block (JB) on the left end of the instrument panel in the passenger compartment of the vehicle. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the JB until further diagnosis is completed. See the fuse and relay layout label affixed to the inside surface of the fuse access panel for horn relay identification and location. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, Refer TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the horn relay from the JB. (Refer to HORN RELAY - REMOVAL) for the procedures. 2. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 4. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, perform the Relay Circuit Test that follows. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair the open circuit to the fuse in the PDC as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. This terminal supplies battery voltage to the horn(s). There should be continuity between the cavity for relay terminal 87 and the horn relay output circuit cavity of each horn wire harness connector at all times. If OK, go to Step 4. If not OK, repair the open circuit to the horn(s) as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay. It is connected to battery voltage and should be hot at all times. Check for battery voltage at the cavity for relay terminal 86. If OK, go to Step 5. If not OK, repair the open circuit to the fuse in the PDC as required. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. It is grounded through the horn switch when the horn switch is depressed. On vehicles equipped with the Remote Keyless Entry (RKE) system, the horn relay coil ground terminal can also be grounded by the Central Timer Module (CTM) in response to certain inputs related to the RKE system or the Vehicle Theft Security System. Check for continuity to ground at the cavity for relay terminal 85. There should be continuity with the horn switch depressed, and no continuity with the horn switch released. If not OK, (Refer to HORN SWITCH DIAGNOSIS AND TESTING). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 7726 Horn Relay: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the fuse access panel by inserting a finger in the finger recess molded into the panel and then pulling the panel sharply away from the left outboard end of the instrument panel. 3. See the fuse and relay layout label affixed to the inside of the fuse access panel for horn relay identification and location. 4. Grasp the horn relay firmly and pull it straight out from the JB. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. See the fuse and relay layout label affixed to the inside of the fuse access panel for the proper horn relay location. 2. Position the horn relay in the proper receptacle in the JB. 3. Align the horn relay terminals with the terminal cavities in the JB receptacle. 4. Push in firmly on the horn relay until the terminals are fully seated in the terminal cavities in the JB receptacle. 5. Insert the tabs on the forward edge of the fuse access panel in the notches on the forward edge of the instrument panel fuse access panel opening. 6. Press the rear edge of the fuse access panel in toward the instrument panel until the panel snaps back into place. 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Park Lamp Relay is located in the Junction Block (JB). Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 7730 Parking Lamp Relay: Diagrams Junction Block (Front View) Park Lamp Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations > Page 7736 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7737 Brake Light Switch: Diagrams Brake Lamp Switch Brake Lamp Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7738 Brake Light Switch: Description and Operation The plunger type brake lamp switch is mounted on a bracket attached to the brake pedal support. CAUTION: The switch can only be adjusted during initial installation. If the switch is not adjusted properly a new switch must be installed. The primary function of the switch is to turn ON the brake lamps during braking. The switch is also used to send signals to components that must know when the brakes are applied, such as the Powertrain Control Module (PCM), which uses the signal to cancel speed control. The CAB uses the brake switch signal to monitor brake pedal application. When the switch contacts open (brakes applied), the CAB receives the brake applied signal. The CAB then monitors the RWAL system to anticipate the need for an RWAL stop. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7739 Brake Light Switch: Testing and Inspection Fig.1 Brake Lamp Switch Terminal Identification The brake lamp switch can be tested with an ohm-meter. The ohmmeter is used to check continuity between the pin terminals. Switch Circuit Identification - Terminals 1 and 2: brake lamp circuit - Terminals 3 and 4: RWAL/ABS module and Powertrain Control Module (PCM) circuit - Terminals 5 and 6: speed control circuit Switch Continuity Test NOTE: Disconnect switch harness before testing switch continuity. With switch plunger extended, attach test leads to pins 1 and 2. Replace switch if meter indicates no continuity. With switch plunger retracted, attach test leads to pins 3 and 4. Replace switch if meter indicates no continuity. With switch plunger retracted, attach test leads to pins 5 and 6. Replace switch if meter indicates no continuity. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7740 Brake Light Switch: Service and Repair Fig.2 Brake Lamp Switch & Bracket REMOVAL 1. Disconnect switch harness. 2. Press and hold brake pedal in applied position. 3. Rotate switch counterclockwise about 300 to align switch lock tab with notch in bracket. 4. Pull switch rearward out of mounting bracket and release brake pedal. INSTALLATION 1. Press and hold brake pedal down. 2. Align tab on new switch with notch in switch bracket. Then insert switch in bracket and turn it clockwise about 30 ° to lock it in place. 3. Connect harness wires to switch. 4. Release brake pedal. 5. Move the release lever on the switch to engage the switch plunger. The switch is now adjusted and can not be adjusted again. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Testing and Inspection Combination Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the multi-function switch from the switch mounting housing on the steering column. (Refer to LAMPS/LIGHTING EXTERIOR/MULTI-FUNCTION SWITCH - REMOVAL). Fig. 20 Multi-Function Switch Tests 2. Using an ohmmeter, perform the continuity and resistance tests at the terminals in the multifunction switch connector receptacle as shown in the Multi-Function Switch Tests chart. 3. If the multi-function switch fails any of the continuity or resistance tests, replace the faulty switch unit as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Testing and Inspection > Page 7744 Combination Switch: Service and Repair REMOVAL WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the steering column opening cover from the instrument panel. 3. If the vehicle is so equipped, grasp the tilt steering column knob firmly and pull it straight rearward to remove it from the tilt steering column adjuster mechanism lever located on the left side of the column just below the multi-function switch control stalk. 4. From below the steering column, remove the two outboard screws that secure the upper shroud to the lower shroud. 5. Push gently inward on both sides of the upper shroud near the parting line between the upper and lower shrouds to release the snap features that secure it to the lower shroud. 6. Remove the upper shroud from the lower shroud. 7. From below the steering column, remove the one center screw that secures the lower shroud to the steering column lock housing. 8. Remove the lower shroud from the steering column. 9. Disconnect the instrument panel wire harness connector for the multi-function switch from the switch connector receptacle. Fig.16 Multi-Function Switch 10. Remove the two screws that secure the multi-function switch to the multi-function switch mounting housing. 11. Grasp the multi-function switch control stalk and pull it straight toward the outboard side of the vehicle to disengage the switch from the multi-function switch mounting housing. INSTALLATION 1. Position the multi-function switch onto the multi-function switch mounting housing. 2. Install and tighten the two screws that secure the multi-function switch to the multi-function switch mounting housing. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the instrument panel wire harness connector for the multi-function switch to the switch connector receptacle. 4. Position the lower shroud onto the steering column. 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column lock housing. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud onto the steering column. If the vehicle is equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the openings in the right side of the upper and lower shrouds. 7. Align the snap features on the upper shroud with the receptacles on the lower shroud and apply hand pressure to snap them together. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Testing and Inspection > Page 7745 8. From below the steering column, install and tighten the two screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). 9. If the vehicle is so equipped, align the tilt steering column knob with the tilt steering column adjuster mechanism lever located on the left side of the column just below the multi-function switch control stalk and using hand pressure push the knob firmly onto the lever. 10. Reinstall the steering column opening cover onto the instrument panel. 11. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions Door Switch: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7750 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7751 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart 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 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7752 Wire 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. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7753 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All 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 and more frequently 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. 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. - 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7754 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7755 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7756 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7757 Fig.18 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 (Fig. 17) (Fig. 18). 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. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. 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. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7758 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7759 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7760 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7761 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7762 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. 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 (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7763 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7764 Door Switch: Diagnostic Aids Intermittent and Poor Connections 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 into 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 or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) 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 and more frequently 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 form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7765 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - 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 about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7766 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - 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 suspected fused circuits. 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 or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. 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 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 vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7767 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). 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 nonfactory 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. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7768 Door Switch: Connector Views Driver Door Power Lock Motor/Ajar Switch Left Rear Door Power Lock Motor/Ajar Switch Passenger Door Power Lock Motor/Ajar Switch Right Rear Door Power Lock Motor/Ajar Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7769 Door Ajar Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 7770 Door Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 7771 Door Switch: Description and Operation DOOR AJAR SWITCH The door ajar switches are integral to the door latches on each door. The switches close a path to ground for the Central Timer Module (CTM) when a door is opened, and open the ground path when a door is closed. The door ajar switches cannot be repaired and, if faulty or damaged, the door latch unit must be replaced. The door ajar switches close a path to ground for the Central Timer Module (CTM) when a door is opened, and opens the ground path when a door is closed. The passenger side front door and both rear door ajar switches are connected in a parallel-series circuit between ground and the CTM, while the driver side front door ajar switch is connected in series between ground and the CTM to provide a unique input. The CTM reads the switch status through an internal pull-up, then sends the proper switch status messages to other electronic modules over the Programmable Communications Interface (PCI) data bus network. The door ajar switches can be diagnosed using conventional diagnostic tools and methods. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 7772 Door Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Disconnect the door latch pigtail wire connector from the door wire harness connector. Check for continuity between the ground circuit cavity in the door wire harness connector and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the open ground circuit to ground as required. 2. Check for continuity between the ground circuit cavity and the driver or passenger door ajar switch sense circuit cavity in the door latch pigtail wire connector. There should be continuity with the door opened, and no continuity with the door closed. If OK, go to Step 3. If not OK, replace the faulty door latch unit. 3. Disconnect the body wire harness connector (Connector C2) for the Central Timer Module (CTM) from the CTM connector receptacle. Check for continuity between the driver or passenger door ajar switch sense circuit cavity of the body wire harness connector (Connector C2) and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, repair the shorted driver or passenger door ajar switch sense circuit between the door latch and the CTM as required. 4. Check for continuity between the driver or passenger door ajar switch sense circuit cavities of the body wire harness connector (Connector C2) and the door wire harness connector for the door latch. There should be continuity. If OK, use a DRB III scan tool to diagnose the CTM. Refer to the appropriate diagnostic procedures. If not OK, repair the open driver or passenger door ajar switch sense circuit between the door latch and the CTM as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Diagrams Glove Box Lamp And Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Diagrams > Page 7776 Glove Box Lamp Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Diagrams > Page 7777 Glove Box Lamp Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Open the glove box. 3. Reach through the glove box opening and behind the glove box opening upper reinforcement in the instrument panel to access and depress the retaining latches on the top and bottom of the glove box lamp and switch housing. Fig. 3 Glove Box Lamp And Switch Remove/Install 4. While holding the retaining latches depressed, push the glove box lamp and switch out through the mounting hole in the instrument panel glove box opening upper reinforcement. 5. Pull the glove box lamp and switch out from the mounting hole far enough to access the wire harness connector. 6. Disconnect the instrument panel wire harness connector from the glove box lamp and switch connector receptacle. 7. Remove the glove box lamp and switch from the instrument panel. INSTALLATION 1. Position the glove box lamp and switch to the instrument panel. 2. Reconnect the instrument panel wire harness connector to the glove box lamp and switch connector receptacle. 3. Feed the instrument panel wire harness back into the glove box lamp and switch mounting hole in the glove box opening upper reinforcement. 4. Align the glove box lamp and switch housing with the mounting hole in the instrument panel glove box opening upper reinforcement. 5. Push the glove box lamp and switch into the mounting hole in the instrument panel glove box opening upper reinforcement until the retaining latches are fully engaged. 6. Close the glove box. 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Multi-Function Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 7781 Hazard Warning Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 7782 Hazard Warning Switch: Description and Operation Fig.14 Multi-Function Switch MULTI-FUNCTION SWITCH The multi-function switch is secured with two screws to the multi-function switch mounting housing on the left side of the steering column, just below the steering wheel. The only visible parts of the multi-function switch are the control stalk that extends through a dedicated opening in the left side of the upper steering column shrouds, and the hazard warning switch push button that protrudes through an opening in the upper steering column shroud on the top of the steering column. The remainder of the switch, its mounting provisions, and its electrical connections are all concealed beneath the steering column shrouds. The multi-function switch control stalk has both nomenclature and International Control and Display Symbol graphics applied to it, which identify its many functions. An International Control and Display Symbol icon for "Hazard Warning" is applied to the top of the hazard warning switch push button. The switch housing and its controls are constructed of molded black plastic. A single connector receptacle connects the switch to the vehicle electrical system through a take out and connector of the instrument panel wire harness. The multi-function switch supports the following functions and features: - Continuous Wipe Modes - The control knob of the multi-function switch provides two continuous wipe switch positions, low speed or high speed. - Hazard Warning Control - The internal circuitry and hardware of the multi-function switch provide detent switching for activation and deactivation of the hazard warning system. - Headlamp Beam Selection - The internal circuitry and hardware of the multi-function switch provide detent switching for selection of the headlamp high or low beams. - Headlamp Optical Horn - The internal circuitry and hardware of the multi-function switch includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Intermittent Wipe Mode - The control knob of the multi-function switch provides an intermittent wipe mode with multiple delay interval positions. - Turn Signal Control - The internal circuitry and hardware of the multi-function switch provide both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signals. - Washer Mode - The control knob of the multi- function switch provides washer system operation when the knob is depressed towards the steering column. The multi-function switch cannot be adjusted or repaired. If any function of the switch is faulty, or if the switch is damaged, the entire switch unit must be replaced. The multi-function switch uses conventionally switched outputs and a variable resistor to control the many functions and features it provides using hard wired circuitry. The switch is grounded at all times through a single wire take out with an eyelet terminal connector of the instrument panel wire harness that is secured by a nut to a ground stud located on the left cowl side inner panel, near the left instrument panel end bracket. When the ignition switch is in the Accessory or ON positions, battery current from a fuse in the Junction Block (JB) is provided through a fused ignition switch output (run acc) circuit. Following are descriptions of how the multi-function switch operates to control the many functions and features it provides: Continuous Wipe Modes - When the control knob of the multi-function switch is rotated to the High or Low positions, the circuitry within the Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 7783 switch provides a battery current output directly to the high or low speed brush of the wiper motor. When the control knob is in the OFF position, the circuitry within the switch connects the output of the wiper motor park switch to the low speed brush of the wiper motor. - Hazard Warning Control - The hazard warning push button is pushed down to unlatch the switch and activate the hazard warning system, and pushed down again to latch the switch and turn the system OFF. When the hazard warning switch is latched (hazard warning OFF), the push button will be in a lowered position on the top of the steering column shroud; and, when the hazard warning switch is unlatched (hazard warning ON), the push button will be in a raised position. The multi-function switch hazard warning circuitry provides a signal to the hazard warning sense of the combination flasher to activate or deactivate the flasher output to the hazard warning lamps. - Headlamp Beam Selection - The multi-function switch control stalk is pulled towards the steering wheel past a detent, then released to actuate the headlamp beam selection switch. Each time the control stalk is actuated in this manner, the opposite headlamp mode from what is currently selected will be activated. The internal circuitry of the headlamp beam selection switch directs a ground signal output from the headlamp switch to the appropriate low beam or high beam sense of the Central Timer Module (CTM). The CTM then controls a hard wired output to activate the selected headlamp beams. - Headlamp Optical Horn - The left multi-function switch control stalk is pulled towards the steering wheel to just before a detent, to momentarily activate the headlamp high beams. The high beams will remain illuminated until the control stalk is released. The internal circuitry of the headlamp beam selection switch provides a momentary ground path to the CTM high beam sense. - Intermittent Wipe Mode - When the multi-function switch control knob is rotated to the Delay position, the circuitry within the switch provides a battery current signal to the Central Timer Module (CTM). If the Delay mode is selected, the control knob can then be rotated to multiple minor detent positions, which actuates a variable resistor within the switch and provides a hard wired output to the CTM that signals the desired delay interval for the intermittent wiper feature. - Turn Signal Control - The multi-function switch control stalk actuates the turn signal switch. When the control stalk is moved in the upward direction, the right turn signal circuitry is activated; and, when the control stalk is moved in the downward direction, the left turn signal circuitry is activated. The multi-function switch turn signal circuitry provides a signal to the right or left turn signal sense of the combination flasher to activate or deactivate the flasher output to the proper turn signal lamps. The turn signal switch has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that provides turn signals only until the multi-function switch control stalk is released. When the control stalk is moved to a turn signal switch detent position, the cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clock-spring mechanism rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. In other words, if the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. - Washer Mode - Pushing the control knob on the end of the multi-function switch control stalk towards the steering column provides a battery current output through the momentary single pole, single throw washer switch circuitry to provide a washer signal input to the CTM. The CTM then provides a battery current output to operate the washer pump/motor. If the wipers are not operating when the washer switch is actuated, the CTM will operate the wiper motor for as long as the washer switch is depressed plus about three additional wipe cycles. If the wipers are operating in the intermittent mode when the washer switch is actuated, the CTM will operate the wiper motor at a fixed low speed for as long as the washer switch is depressed plus about three additional wipe cycles before the wipers return to the selected intermittent wipe interval. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations The headlamp switch is located in the instrument panel, outboard of the steering column. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 7787 Headlamp Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 7788 Headlamp Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 7789 Headlamp Switch: Description and Operation The headlamp switch is located in the instrument panel, outboard of the steering column. It closes a path to ground for the Central Timer Module (CTM) when the park or head lamps are ON and the driver door ajar switch is closed (driver door is open). The headlamp switch opens the ground path when the headlamp switch is turned OFF. The ground path is also opened when the driver door ajar switch is open (driver door is closed). This switch also contains a rheostat for controlling the illumination level of the instrument cluster lamps. The headlamp switch cannot be repaired and, if faulty or damaged, it must be replaced. The headlamp switch has an OFF position, a parking lamp position, and a headlamp ON position. High beams are controlled by the multifunction switch on the steering column. The headlamp switch cannot be repaired. It must be replaced. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 7790 Headlamp Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the headlamp switch. (Refer to HEADLAMP SWITCH - REMOVAL). Headlamp Switch Continuity Table Fig. 14 Headlamp Switch 2. Using an ohmmeter, test for continuity between the terminals of the switch as shown in the Headlamp Switch Continuity table. 3. If test results are not obtained as shown in the Headlamp Switch Continuity table, replace the headlamp switch. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 7791 Headlamp Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel from the instrument panel. 3. Disconnect the wire harness connector from the headlamp switch. 4. Remove the headlamp switch from the cluster bezel. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the headlamp switch to the cluster bezel. 2. Install and tighten the screws that secure the headlamp switch. Tighten the screws to 2.2 Nm (20 in. lbs.). 3. Reconnect the wire harness to the headlamp switch. 4. Install the cluster bezel onto the instrument panel. 5. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service Precautions Horn Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service Precautions > Page 7795 Horn Switch: Description and Operation Fig. 3 Driver Side Airbag Module Trim Cover And Horn Switch A center-blow, normally open, resistive membrane-type horn switch is secured with heat stakes to the back side of the driver side airbag module trim cover in the center of the steering wheel . The switch consists of two plastic membranes, one that is flat and one that is slightly convex. These two membranes are secured to each other around the perimeter. Inside the switch, the centers of the facing surfaces of these membranes each has a grid made with an electrically conductive material applied to it. One of the grids is connected to a circuit that provides it with continuity to ground at all times. The grid of the other membrane is connected to the horn relay control circuit. The steering wheel and steering column must be properly grounded in order for the horn switch to function properly. The horn switch is only serviced as a part of the driver side airbag module trim cover. If the horn switch is damaged or faulty, or if the driver side airbag is deployed, the driver side airbag module trim cover and horn switch must be replaced as a unit. When the center area of the driver side airbag trim cover is depressed, the electrically conductive grids on the facing surfaces of the horn switch membranes contact each other, closing the switch circuit. The completed horn switch circuit provides a ground for the control coil side of the horn relay, which activates the relay. When the horn switch is released, the resistive tension of the convex membrane separates the two electrically conductive grids and opens the switch circuit. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service Precautions > Page 7796 Horn Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Remove the steering column opening cover from the instrument panel. 2. Check for continuity between the metal steering column jacket and a good ground. There should be continuity. If OK, go to Step 3. 3. Remove the driver side airbag module from the steering wheel. Disconnect the horn switch wire harness connectors from the driver side airbag module. 4. Remove the horn relay from the Junction Block (JB). Check for continuity between the steering column half of the horn switch feed wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted horn relay control circuit to the horn relay in the JB as required. 5. Check for continuity between the steering column half of the horn switch feed wire harness connector and the horn relay control circuit cavity for the horn relay in the JB. There should be continuity. If OK, go to Step 6. If not OK, repair the open horn relay control circuit to the horn relay in the JB as required. 6. Check for continuity between the horn switch feed wire and the horn switch ground wire on the driver side airbag module. There should be no continuity. If OK, go to Step 7. If not OK, replace the faulty horn switch. 7. Depress the center of the driver side airbag module trim cover and check for continuity between the horn switch feed wire and the horn switch ground wire on the driver side airbag module. There should now be continuity. If not OK, replace the faulty horn switch. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Multi-Function Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 7800 Turn Signal Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 7801 Turn Signal Switch: Description and Operation Fig.14 Multi-Function Switch MULTI-FUNCTION SWITCH The multi-function switch is secured with two screws to the multi-function switch mounting housing on the left side of the steering column, just below the steering wheel. The only visible parts of the multi-function switch are the control stalk that extends through a dedicated opening in the left side of the upper steering column shrouds, and the hazard warning switch push button that protrudes through an opening in the upper steering column shroud on the top of the steering column. The remainder of the switch, its mounting provisions, and its electrical connections are all concealed beneath the steering column shrouds. The multi-function switch control stalk has both nomenclature and International Control and Display Symbol graphics applied to it, which identify its many functions. An International Control and Display Symbol icon for "Hazard Warning" is applied to the top of the hazard warning switch push button. The switch housing and its controls are constructed of molded black plastic. A single connector receptacle connects the switch to the vehicle electrical system through a take out and connector of the instrument panel wire harness. The multi-function switch supports the following functions and features: - Continuous Wipe Modes - The control knob of the multi-function switch provides two continuous wipe switch positions, low speed or high speed. - Hazard Warning Control - The internal circuitry and hardware of the multi-function switch provide detent switching for activation and deactivation of the hazard warning system. - Headlamp Beam Selection - The internal circuitry and hardware of the multi-function switch provide detent switching for selection of the headlamp high or low beams. - Headlamp Optical Horn - The internal circuitry and hardware of the multi-function switch includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Intermittent Wipe Mode - The control knob of the multi-function switch provides an intermittent wipe mode with multiple delay interval positions. - Turn Signal Control - The internal circuitry and hardware of the multi-function switch provide both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signals. - Washer Mode - The control knob of the multi- function switch provides washer system operation when the knob is depressed towards the steering column. The multi-function switch cannot be adjusted or repaired. If any function of the switch is faulty, or if the switch is damaged, the entire switch unit must be replaced. The multi-function switch uses conventionally switched outputs and a variable resistor to control the many functions and features it provides using hard wired circuitry. The switch is grounded at all times through a single wire take out with an eyelet terminal connector of the instrument panel wire harness that is secured by a nut to a ground stud located on the left cowl side inner panel, near the left instrument panel end bracket. When the ignition switch is in the Accessory or ON positions, battery current from a fuse in the Junction Block (JB) is provided through a fused ignition switch output (run acc) circuit. Following are descriptions of how the multi-function switch operates to control the many functions and features it provides: Continuous Wipe Modes - When the control knob of the multi-function switch is rotated to the High or Low positions, the circuitry within the Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 7802 switch provides a battery current output directly to the high or low speed brush of the wiper motor. When the control knob is in the OFF position, the circuitry within the switch connects the output of the wiper motor park switch to the low speed brush of the wiper motor. - Hazard Warning Control - The hazard warning push button is pushed down to unlatch the switch and activate the hazard warning system, and pushed down again to latch the switch and turn the system OFF. When the hazard warning switch is latched (hazard warning OFF), the push button will be in a lowered position on the top of the steering column shroud; and, when the hazard warning switch is unlatched (hazard warning ON), the push button will be in a raised position. The multi-function switch hazard warning circuitry provides a signal to the hazard warning sense of the combination flasher to activate or deactivate the flasher output to the hazard warning lamps. - Headlamp Beam Selection - The multi-function switch control stalk is pulled towards the steering wheel past a detent, then released to actuate the headlamp beam selection switch. Each time the control stalk is actuated in this manner, the opposite headlamp mode from what is currently selected will be activated. The internal circuitry of the headlamp beam selection switch directs a ground signal output from the headlamp switch to the appropriate low beam or high beam sense of the Central Timer Module (CTM). The CTM then controls a hard wired output to activate the selected headlamp beams. - Headlamp Optical Horn - The left multi-function switch control stalk is pulled towards the steering wheel to just before a detent, to momentarily activate the headlamp high beams. The high beams will remain illuminated until the control stalk is released. The internal circuitry of the headlamp beam selection switch provides a momentary ground path to the CTM high beam sense. - Intermittent Wipe Mode - When the multi-function switch control knob is rotated to the Delay position, the circuitry within the switch provides a battery current signal to the Central Timer Module (CTM). If the Delay mode is selected, the control knob can then be rotated to multiple minor detent positions, which actuates a variable resistor within the switch and provides a hard wired output to the CTM that signals the desired delay interval for the intermittent wiper feature. - Turn Signal Control - The multi-function switch control stalk actuates the turn signal switch. When the control stalk is moved in the upward direction, the right turn signal circuitry is activated; and, when the control stalk is moved in the downward direction, the left turn signal circuitry is activated. The multi-function switch turn signal circuitry provides a signal to the right or left turn signal sense of the combination flasher to activate or deactivate the flasher output to the proper turn signal lamps. The turn signal switch has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that provides turn signals only until the multi-function switch control stalk is released. When the control stalk is moved to a turn signal switch detent position, the cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clock-spring mechanism rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. In other words, if the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. - Washer Mode - Pushing the control knob on the end of the multi-function switch control stalk towards the steering column provides a battery current output through the momentary single pole, single throw washer switch circuitry to provide a washer signal input to the CTM. The CTM then provides a battery current output to operate the washer pump/motor. If the wipers are not operating when the washer switch is actuated, the CTM will operate the wiper motor for as long as the washer switch is depressed plus about three additional wipe cycles. If the wipers are operating in the intermittent mode when the washer switch is actuated, the CTM will operate the wiper motor at a fixed low speed for as long as the washer switch is depressed plus about three additional wipe cycles before the wipers return to the selected intermittent wipe interval. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams Tail Lamp: Diagrams Left Tail Lamp Assembly Right Tail Lamp Assembly Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 7806 Tail Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Table Tail, Brake, Turn Signal and Side Marker ............................................................................................................................................................ 3057 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 7807 Tail Lamp: Description and Operation TAIL LAMP UNIT The taillamps on the Durango are mounted at the rear of the vehicle, outboard of the rear hatch and integrated into the lines of the vehicle. The taillamp module contains a housing, lens, and three bulbs. Dual filament bulb is used for tail, stop, and turn signal operations. A separate bulb is used for back-up illumination. Tail lamp functions are controlled by the headlamp switch. Turn signal operations are controlled by the multifunction switch. Stop lamp functions are controlled by the stoplamp switch. The back-up lamps are controlled by the back-up lamp switch on the transmission. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Service and Repair > Tail Lamp Replacement Tail Lamp: Service and Repair Tail Lamp Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Release liftgate latch and open liftgate. 3. Remove screws attaching tail lamp to liftgate opening. 4. Separate inner end of lamp from quarter panel. 5. Disengage hook holding outer end of lamp to quarter panel opening. 6. Separate lamp from quarter panel. Fig. 22 Tail, Brake, Turn Signal And Back-up Lamp Bulb 7. Rotate lamp socket counterclockwise one quarter turn. 8. Pull socket from back of lamp. Pull Bulb From Socket 9. Pull bulb from socket. INSTALLATION 1. Align key on bulb base to groove in socket and insert bulb into socket. 2. Insert socket into back of lamp. 3. Rotate lamp socket clockwise one quarter turn. 4. Engage hook to hold outer end of lamp to quarter panel opening. 5. Place lamp in position on quarter panel. 6. Install screws attaching lamp to liftgate opening. 7. Connect battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Service and Repair > Tail Lamp Replacement > Page 7810 Tail Lamp: Service and Repair Tail Lamp Unit Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Release liftgate latch and open liftgate. Fig. 24 Tail, Brake, Turn Signal And Back-up Lamp 3. Remove screws attaching tail, brake, turn signal and back-up lamp to liftgate opening. 4. Separate inner end of lamp from quarter panel. 5. Disengage hook holding outer end of lamp to quarter panel opening. 6. Separate lamp from quarter panel. Fig. 25 Tail Lamp Connector 7. Disengage positive lock on wire connector. 8. Depress lock tab on the side of the body harness connector. 9. Disengage wire connector from tail lamp circuit board. 10. Separate tail lamp from vehicle. INSTALLATION 1. Place tail lamp in position on vehicle. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Service and Repair > Tail Lamp Replacement > Page 7811 2. Engage wire connector into tail lamp circuit board. 3. Engage positive lock on wire connector. 4. Place lamp in position on quarter panel. 5. Engage hook to hold outer end of lamp to quarter panel opening. 6. Position inner end of lamp into quarter panel. 7. Install screws attaching tail, stop, turn signal and back-up lamp to liftgate opening. 8. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Testing and Inspection Combination Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the multi-function switch from the switch mounting housing on the steering column. (Refer to LAMPS/LIGHTING EXTERIOR/MULTI-FUNCTION SWITCH - REMOVAL). Fig. 20 Multi-Function Switch Tests 2. Using an ohmmeter, perform the continuity and resistance tests at the terminals in the multifunction switch connector receptacle as shown in the Multi-Function Switch Tests chart. 3. If the multi-function switch fails any of the continuity or resistance tests, replace the faulty switch unit as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Testing and Inspection > Page 7816 Combination Switch: Service and Repair REMOVAL WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the steering column opening cover from the instrument panel. 3. If the vehicle is so equipped, grasp the tilt steering column knob firmly and pull it straight rearward to remove it from the tilt steering column adjuster mechanism lever located on the left side of the column just below the multi-function switch control stalk. 4. From below the steering column, remove the two outboard screws that secure the upper shroud to the lower shroud. 5. Push gently inward on both sides of the upper shroud near the parting line between the upper and lower shrouds to release the snap features that secure it to the lower shroud. 6. Remove the upper shroud from the lower shroud. 7. From below the steering column, remove the one center screw that secures the lower shroud to the steering column lock housing. 8. Remove the lower shroud from the steering column. 9. Disconnect the instrument panel wire harness connector for the multi-function switch from the switch connector receptacle. Fig.16 Multi-Function Switch 10. Remove the two screws that secure the multi-function switch to the multi-function switch mounting housing. 11. Grasp the multi-function switch control stalk and pull it straight toward the outboard side of the vehicle to disengage the switch from the multi-function switch mounting housing. INSTALLATION 1. Position the multi-function switch onto the multi-function switch mounting housing. 2. Install and tighten the two screws that secure the multi-function switch to the multi-function switch mounting housing. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the instrument panel wire harness connector for the multi-function switch to the switch connector receptacle. 4. Position the lower shroud onto the steering column. 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column lock housing. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud onto the steering column. If the vehicle is equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the openings in the right side of the upper and lower shrouds. 7. Align the snap features on the upper shroud with the receptacles on the lower shroud and apply hand pressure to snap them together. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Testing and Inspection > Page 7817 8. From below the steering column, install and tighten the two screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). 9. If the vehicle is so equipped, align the tilt steering column knob with the tilt steering column adjuster mechanism lever located on the left side of the column just below the multi-function switch control stalk and using hand pressure push the knob firmly onto the lever. 10. Reinstall the steering column opening cover onto the instrument panel. 11. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations Turn Signal Flasher: Locations The electronic combination flasher is installed in a dedicated connector of the instrument panel wire harness located under the instrument panel outboard of the steering column opening. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 7821 Turn Signal Flasher: Diagrams Combination Flasher Combination Flasher Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 7822 Turn Signal Flasher: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 7823 Turn Signal Flasher: Description and Operation Fig. 4 Combination Flasher COMBINATION FLASHER The combination flasher is located in a dedicated connector on a take out of the instrument panel wire harness, located under the instrument panel just outboard of the instrument panel steering column opening. The combination flasher is a smart relay that functions as both the turn signal system and the hazard warning system flasher. The combination flasher has fourteen blade-type terminals that connect it to the vehicle electrical system through fourteen matching cavities in the instrument panel wire harness connector; however, only ten of the combination flasher terminals are used in this application. The combination flasher contains active electronic Integrated Circuitry (IC) elements. This flasher is designed to handle the current flow requirements of the factory-installed lighting. If supplemental lighting is added to the turn signal lamp circuits, such as when towing a trailer with lights, the combination flasher will automatically try to compensate to keep the flash rate the same. The combination flasher cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. The combination flasher has fourteen blade-type terminals, but only ten are used in this application. These ten terminals are intended for the following inputs and outputs: fused B(+), fused ignition switch output, right turn signal sense, left turn signal sense, hazard flasher signal, brake lamp switch output, and two outputs each for the right and left turn signal circuits. Constant battery voltage is supplied to the flasher so that it can perform the hazard warning function, and ignition switched battery voltage is supplied for the turn signal function. The Integrated Circuit (IC) within the combination flasher contains the logic that controls the flasher operation and the flash rate. The IC receives separate sense ground inputs from the multi-function switch for the hazard flasher, right turn signal, and left turn signal. A special design feature of the combination flasher allows it to "sense" that a turn signal circuit or bulb is not operating, and provide the driver an indication of the condition by flashing the remaining bulbs in the affected circuit at a higher rate (120 flashes-per-minute or higher). Conventional flashers either continue flashing at their typical rate (heavy-duty type), or discontinue flashing the affected circuit entirely (standard-duty type). Because of the active electronic elements within the combination flasher, it cannot be tested with conventional automotive electrical test equipment. If the combination flasher is believed to be faulty, test the turn signal and hazard warning system. Then replace the combination flasher with a known good unit to confirm system operation. (Refer to TURN SIGNAL & HAZARD WARNING SYSTEM DIAGNOSIS AND TESTING). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 7824 Turn Signal Flasher: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Fig. 5 Combination Flasher 2. Reach under the outboard side of the steering column opening in the instrument panel to access the instrument panel wire harness connector for the combination flasher located on a mounting tab on the back of the instrument panel armature. 3. Grasp the combination flasher and connector firmly and pull them toward the dash panel to disengage the connector from the mounting tab on the instrument panel armature. 4. Remove the combination flasher from the instrument panel wire harness connector. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the combination flasher to the instrument panel wire harness connector. 2. Align the combination flasher terminals with the terminal cavities in the instrument panel wire harness connector. 3. Using hand pressure, push in firmly on the combination flasher until the terminals are fully seated in the terminal cavities in the instrument panel wire harness connector. 4. Align the slot in the combination flasher connector with the mounting tab on the instrument panel armature. 5. Using hand pressure, push the combination flasher connector firmly onto the mounting tab until it is fully engaged in the slot. 6. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Locations Turn Signal Indicator: Locations The turn signal indicators are located near the upper edge of the instrument cluster overlay, between the speedometer and the tachometer. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Locations > Page 7828 Turn Signal Indicator: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. - Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Table Front Park/Turn Signal ........................................................................................................................ .................................................................. 3157 Tail, Brake, Turn Signal and Side Marker ............................................................................................................................................................ 3057 Turn Signal ................................................................................................................................. ........................................................................ PC194 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Locations > Page 7829 Turn Signal Indicator: Description and Operation Two turn signal indicators, one right and one left, are standard equipment on all instrument clusters. The turn signal indicators are located near the upper edge of the instrument cluster overlay, between the speedometer and the tachometer. Each turn signal indicator consists of a stenciled cutout of the International Control and Display Symbol icon for "Turn Warning" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents these icons from being clearly visible when their lamps are not illuminated. The icons appear in green through the translucent outer layer of the overlay when the indicator is illuminated from behind by a replaceable incandescent bulb and bulb holder unit located on the instrument cluster electronic circuit board. The turn signal indicators are serviced as a unit with the instrument cluster. The turn signal indicators give an indication to the vehicle operator that the turn signal (left or right indicator flashing) or hazard warning (both left and right indicators flashing) have been selected. These indicators are controlled by two individual hard wired inputs to the instrument cluster electronic circuit board. The turn signal indicator bulbs are grounded on the instrument cluster electronic circuit board at all times. The turn signal indicator bulbs only illuminate when they are provided with battery current by the turn signal and hazard warning circuitry of the combination flasher through separate left and right turn signal circuit inputs to the instrument cluster; therefore, these indicators can be illuminated, regardless of the ignition switch position. The turn signal indicators are connected in series between ground and the output of the combination flasher circuitry, but in parallel with the other turn signal circuits. This arrangement allows the turn signal indicators to remain functional regardless of the condition of the other circuits in the turn signal and hazard warning system. For more information on the turn signal and hazard warning system, (Refer to LIGHTING - TURN SIGNAL & HAZARD WARNING SYSTEM). The turn signal indicators can be diagnosed using conventional diagnostic tools and methods. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Locations > Page 7830 Turn Signal Indicator: Testing and Inspection The diagnosis found here addresses an inoperative turn signal indicator condition. If the problem being diagnosed is related to inoperative turn signals or hazard warning lamps, be certain to repair the turn signal and hazard warning system before attempting to diagnose or repair the turn signal indicators. If no turn signal or hazard warning system problems are found, the following procedure will help locate a short or open in the left or right turn signal indicator circuits. 1. Disconnect and isolate the battery negative cable. Remove the instrument cluster. 2. Connect the battery negative cable. Activate the hazard warning system by moving the hazard warning switch button to the ON position. Check for battery voltage at the inoperative (right or left) turn signal circuit cavity of the instrument panel wire harness connector (Connector C2) for the instrument cluster. There should be a switching (on and OFF) battery voltage signal. If OK, replace the faulty turn signal indicator bulb. If not OK, repair the open (right or left) turn signal circuit between the instrument cluster and the combination flasher as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair Turn Signal Bulb: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove park and turn signal lamp. Fig. 18 Park And Turn Signal Lamp Bulb 3. Rotate bulb socket 1/4 turn counterclockwise and pull turn signal lamp socket from back of lamp. 4. Pull park and turn signal lamp bulb from socket. INSTALLATION 1. Install park and turn signal lamp bulb in socket. 2. Install park and turn signal lamp socket into back of lamp. 3. Install park/turn signal lamp. 4. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams Multi-Function Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 7838 Turn Signal Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 7839 Turn Signal Switch: Description and Operation Fig.14 Multi-Function Switch MULTI-FUNCTION SWITCH The multi-function switch is secured with two screws to the multi-function switch mounting housing on the left side of the steering column, just below the steering wheel. The only visible parts of the multi-function switch are the control stalk that extends through a dedicated opening in the left side of the upper steering column shrouds, and the hazard warning switch push button that protrudes through an opening in the upper steering column shroud on the top of the steering column. The remainder of the switch, its mounting provisions, and its electrical connections are all concealed beneath the steering column shrouds. The multi-function switch control stalk has both nomenclature and International Control and Display Symbol graphics applied to it, which identify its many functions. An International Control and Display Symbol icon for "Hazard Warning" is applied to the top of the hazard warning switch push button. The switch housing and its controls are constructed of molded black plastic. A single connector receptacle connects the switch to the vehicle electrical system through a take out and connector of the instrument panel wire harness. The multi-function switch supports the following functions and features: - Continuous Wipe Modes - The control knob of the multi-function switch provides two continuous wipe switch positions, low speed or high speed. - Hazard Warning Control - The internal circuitry and hardware of the multi-function switch provide detent switching for activation and deactivation of the hazard warning system. - Headlamp Beam Selection - The internal circuitry and hardware of the multi-function switch provide detent switching for selection of the headlamp high or low beams. - Headlamp Optical Horn - The internal circuitry and hardware of the multi-function switch includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Intermittent Wipe Mode - The control knob of the multi-function switch provides an intermittent wipe mode with multiple delay interval positions. - Turn Signal Control - The internal circuitry and hardware of the multi-function switch provide both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signals. - Washer Mode - The control knob of the multi- function switch provides washer system operation when the knob is depressed towards the steering column. The multi-function switch cannot be adjusted or repaired. If any function of the switch is faulty, or if the switch is damaged, the entire switch unit must be replaced. The multi-function switch uses conventionally switched outputs and a variable resistor to control the many functions and features it provides using hard wired circuitry. The switch is grounded at all times through a single wire take out with an eyelet terminal connector of the instrument panel wire harness that is secured by a nut to a ground stud located on the left cowl side inner panel, near the left instrument panel end bracket. When the ignition switch is in the Accessory or ON positions, battery current from a fuse in the Junction Block (JB) is provided through a fused ignition switch output (run acc) circuit. Following are descriptions of how the multi-function switch operates to control the many functions and features it provides: Continuous Wipe Modes - When the control knob of the multi-function switch is rotated to the High or Low positions, the circuitry within the Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 7840 switch provides a battery current output directly to the high or low speed brush of the wiper motor. When the control knob is in the OFF position, the circuitry within the switch connects the output of the wiper motor park switch to the low speed brush of the wiper motor. - Hazard Warning Control - The hazard warning push button is pushed down to unlatch the switch and activate the hazard warning system, and pushed down again to latch the switch and turn the system OFF. When the hazard warning switch is latched (hazard warning OFF), the push button will be in a lowered position on the top of the steering column shroud; and, when the hazard warning switch is unlatched (hazard warning ON), the push button will be in a raised position. The multi-function switch hazard warning circuitry provides a signal to the hazard warning sense of the combination flasher to activate or deactivate the flasher output to the hazard warning lamps. - Headlamp Beam Selection - The multi-function switch control stalk is pulled towards the steering wheel past a detent, then released to actuate the headlamp beam selection switch. Each time the control stalk is actuated in this manner, the opposite headlamp mode from what is currently selected will be activated. The internal circuitry of the headlamp beam selection switch directs a ground signal output from the headlamp switch to the appropriate low beam or high beam sense of the Central Timer Module (CTM). The CTM then controls a hard wired output to activate the selected headlamp beams. - Headlamp Optical Horn - The left multi-function switch control stalk is pulled towards the steering wheel to just before a detent, to momentarily activate the headlamp high beams. The high beams will remain illuminated until the control stalk is released. The internal circuitry of the headlamp beam selection switch provides a momentary ground path to the CTM high beam sense. - Intermittent Wipe Mode - When the multi-function switch control knob is rotated to the Delay position, the circuitry within the switch provides a battery current signal to the Central Timer Module (CTM). If the Delay mode is selected, the control knob can then be rotated to multiple minor detent positions, which actuates a variable resistor within the switch and provides a hard wired output to the CTM that signals the desired delay interval for the intermittent wiper feature. - Turn Signal Control - The multi-function switch control stalk actuates the turn signal switch. When the control stalk is moved in the upward direction, the right turn signal circuitry is activated; and, when the control stalk is moved in the downward direction, the left turn signal circuitry is activated. The multi-function switch turn signal circuitry provides a signal to the right or left turn signal sense of the combination flasher to activate or deactivate the flasher output to the proper turn signal lamps. The turn signal switch has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that provides turn signals only until the multi-function switch control stalk is released. When the control stalk is moved to a turn signal switch detent position, the cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clock-spring mechanism rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. In other words, if the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. - Washer Mode - Pushing the control knob on the end of the multi-function switch control stalk towards the steering column provides a battery current output through the momentary single pole, single throw washer switch circuitry to provide a washer signal input to the CTM. The CTM then provides a battery current output to operate the washer pump/motor. If the wipers are not operating when the washer switch is actuated, the CTM will operate the wiper motor for as long as the washer switch is depressed plus about three additional wipe cycles. If the wipers are operating in the intermittent mode when the washer switch is actuated, the CTM will operate the wiper motor at a fixed low speed for as long as the washer switch is depressed plus about three additional wipe cycles before the wipers return to the selected intermittent wipe interval. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Underhood Lamp > Component Information > Application and ID Underhood Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Underhood ........................................................................................................................................... .................................................................... 105 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams Vanity Lamp: Diagrams Left Visor/Vanity Lamp Right Visor/Vanity Lamp Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Rear Window Defogger Relay <--> [Heated Glass Element Relay] > Component Information > Locations Rear Window Defogger Relay: Locations Power Distribution Center Rear Defogger Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Rear Window Defogger Relay <--> [Heated Glass Element Relay] > Component Information > Locations > Page 7852 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Rear Window Defogger Relay <--> [Heated Glass Element Relay] > Component Information > Locations > Page 7853 Rear Window Defogger Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Rear Window Defogger Relay <--> [Heated Glass Element Relay] > Component Information > Locations > Page 7854 Rear Window Defogger Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Service Precautions Rear Window Defogger Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Service Precautions > Page 7858 Rear Window Defogger Switch: Description and Operation The rear window defogger switch is integral to the heater-A/C control assembly, which includes the rear wiper and washer switches. The rear window switch also contains the rear window defogger logic and timer circuitry, an amber defogger indicator lamp, the rear window defogger relay, and two switch illumination lamps. The indicator and illumination lamps in the switch pod use incandescent bulbs, which can be serviced. The momentary-type rear window defogger switch provides a hard wired ground signal to the rear window defogger logic and timer circuitry, each time it is depressed. The rear window defogger timer and logic circuitry responds by energizing or de-energizing the rear window defogger relay and the amber defogger indicator lamp, which lights to indicate when the defogger system is turned ON. Energizing the rear window defogger relay provides electrical current to the rear window defogger grid. The rear window switch cannot be repaired. If any function of the switch except lighting is faulty or damaged, the entire heater-A/C control assembly must be replaced. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Service Precautions > Page 7859 Rear Window Defogger Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Remove the lower bezel from the instrument panel and unplug the rear window switch wire harness connector. 2. Check for continuity between the ground circuit cavity of the rear window switch wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open circuit as required. 3. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the rear window switch pod wire harness connector. If OK, go to Step 4. If not OK, repair the circuit to the Power Distribution Center (PDC) fuse as required. 4. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run) circuit cavity of the rear window switch wire harness connector. If OK, go to Step 5. If not OK, repair the circuit to the junction block fuse as required. 5. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Plug the wire harness connector into the rear window switch. Connect the battery negative cable. Turn the ignition switch to the ON position. Back probe the rear window defogger relay output circuit cavity of the rear window switch pod wire harness connector. Depress and release the rear window defogger switch. There should be battery voltage. Depress and release the rear window defogger switch again. There should be zero volts. If OK, go to Step 6. If not OK, replace the faulty rear window switch pod. 6. Depress and release the rear window defogger switch. The rear window defogger indicator lamp should light. If the indicator lamp does not light, replace the bulb with a known good unit and test again. If the lamp is still inoperative, replace the faulty heater-A/C control assembly. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Service Precautions > Page 7860 Rear Window Defogger Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the heater-A/C Control assembly (Refer to HEATING & AIR CONDITIONING/CONTROLS/A/C HEATER CONTROL - REMOVAL). Note: Rear Window Defogger Switch is part of the heater-A/C Control assembly and is not a replaceable component. If damaged or inoperative the entire heater-A/C control assembly must be replaced. INSTALLATION 1. Install the heater-A/C control assembly (Refer to HEATING & AIR CONDITIONING/CONTROLS/A/C HEATER CONTROL INSTALLATION). 2. Install the negative battery cable. Note: The rear window defogger switch is part of the heater-A/C Control assembly, if damaged or inoperative the entire heater-A/C Control assembly must be replaced. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Rear Window Defogger Relay <--> [Heated Glass Element Relay] > Component Information > Locations Rear Window Defogger Relay: Locations Power Distribution Center Rear Defogger Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Rear Window Defogger Relay <--> [Heated Glass Element Relay] > Component Information > Locations > Page 7865 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Rear Window Defogger Relay <--> [Heated Glass Element Relay] > Component Information > Locations > Page 7866 Rear Window Defogger Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Rear Window Defogger Relay <--> [Heated Glass Element Relay] > Component Information > Locations > Page 7867 Rear Window Defogger Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Service Precautions Rear Window Defogger Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Service Precautions > Page 7872 Rear Window Defogger Switch: Description and Operation The rear window defogger switch is integral to the heater-A/C control assembly, which includes the rear wiper and washer switches. The rear window switch also contains the rear window defogger logic and timer circuitry, an amber defogger indicator lamp, the rear window defogger relay, and two switch illumination lamps. The indicator and illumination lamps in the switch pod use incandescent bulbs, which can be serviced. The momentary-type rear window defogger switch provides a hard wired ground signal to the rear window defogger logic and timer circuitry, each time it is depressed. The rear window defogger timer and logic circuitry responds by energizing or de-energizing the rear window defogger relay and the amber defogger indicator lamp, which lights to indicate when the defogger system is turned ON. Energizing the rear window defogger relay provides electrical current to the rear window defogger grid. The rear window switch cannot be repaired. If any function of the switch except lighting is faulty or damaged, the entire heater-A/C control assembly must be replaced. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Service Precautions > Page 7873 Rear Window Defogger Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Remove the lower bezel from the instrument panel and unplug the rear window switch wire harness connector. 2. Check for continuity between the ground circuit cavity of the rear window switch wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open circuit as required. 3. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the rear window switch pod wire harness connector. If OK, go to Step 4. If not OK, repair the circuit to the Power Distribution Center (PDC) fuse as required. 4. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run) circuit cavity of the rear window switch wire harness connector. If OK, go to Step 5. If not OK, repair the circuit to the junction block fuse as required. 5. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Plug the wire harness connector into the rear window switch. Connect the battery negative cable. Turn the ignition switch to the ON position. Back probe the rear window defogger relay output circuit cavity of the rear window switch pod wire harness connector. Depress and release the rear window defogger switch. There should be battery voltage. Depress and release the rear window defogger switch again. There should be zero volts. If OK, go to Step 6. If not OK, replace the faulty rear window switch pod. 6. Depress and release the rear window defogger switch. The rear window defogger indicator lamp should light. If the indicator lamp does not light, replace the bulb with a known good unit and test again. If the lamp is still inoperative, replace the faulty heater-A/C control assembly. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Service Precautions > Page 7874 Rear Window Defogger Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the heater-A/C Control assembly (Refer to HEATING & AIR CONDITIONING/CONTROLS/A/C HEATER CONTROL - REMOVAL). Note: Rear Window Defogger Switch is part of the heater-A/C Control assembly and is not a replaceable component. If damaged or inoperative the entire heater-A/C control assembly must be replaced. INSTALLATION 1. Install the heater-A/C control assembly (Refer to HEATING & AIR CONDITIONING/CONTROLS/A/C HEATER CONTROL INSTALLATION). 2. Install the negative battery cable. Note: The rear window defogger switch is part of the heater-A/C Control assembly, if damaged or inoperative the entire heater-A/C Control assembly must be replaced. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams Power Window Switch: Diagrams Left Rear Door Power Window Switch Passenger Door Power Window Switch Right Rear Door Power Window Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 7878 Power Window Switch: Description and Operation The power windows are controlled by two-way switches integral to the power window and lock switch and bezel unit on the trim panel of each front door. A second power window switch in the driver side switch and bezel unit allows the driver to control the passenger windows. The power window switch for the driver side front door window has an Auto label on it. This switch has a second detent position beyond the normal Down position that provides an automatic one-touch window down feature. This feature is controlled by an electronic circuit and a relay that are integral to the Driver Door Module. The power window switches control the battery and ground feeds to the power window motors. All of the passenger door power window switches receive their battery and ground feeds through the circuitry of the Driver Door Module. When the power window lockout switch is in the Lock position, the battery feed for the individual passenger door power window switches is interrupted. A Light-Emitting Diode (LED) in the paddle of each switch is illuminated whenever the ignition switch is in the ON position. However, the LEDs for the passenger power window switches are extinguished whenever the driver selects the Lock position with the power window lockout switch. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 7879 Power Window Switch: Testing and Inspection The Light-Emitting Diode (LED) illumination lamps for all of the power window and lock switch and bezel unit switch paddles receive battery current through the power window circuit breaker in the junction block. If all of the LEDs are inoperative in both the power window and lock switch units and the power windows are inoperative, (Refer to POWER WINDOWS - DIAGNOSIS AND TESTING). If the power windows operate, but any or all of the LEDs are inoperative, the power window and lock switch units with the inoperative LED(s) is faulty and must be replaced. 1. Check the circuit breaker in the junction block. If OK, go to Step 2. If not OK, replace the faulty circuit breaker. 2. Turn the ignition switch to the ON position. Check for battery voltage at the circuit breaker in the junction block. If OK, turn the ignition switch to the OFF position and go to Step 3. If not OK, repair the circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Remove the power window switch unit from the door trim panel (passenger doors). The drivers door switch is included with the Driver Door Module (Refer to POWER LOCKS/DOOR MODULE DIAGNOSIS AND TESTING) for service procedures. Unplug the wire harness connector from the switch unit, Passenger Door Switch 4. Test the power window switch continuity. See the Power Window Switch Continuity charts to determine if the continuity is correct in the OFF, Up and Down switch positions. If OK, (Refer to WINDOW MOTOR - DIAGNOSIS AND TESTING). If not OK, replace the faulty switch. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 7880 Power Window Switch: Service and Repair REMOVAL The driver side power window switch is included with the Drive Door Module. (Refer to POWER LOCKS/DOOR MODULE - REMOVAL) for the service procedures. 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick, start at the rear of the switch bezel and pry up from door trim panel 3. Disconnect the wire harness connector from switch. 4. Remove switch from bezel. INSTALLATION The driver side power window switch is included with the Drive Door Module. (Refer to POWER LOCKS/DOOR MODULE - INSTALLATION) for the service procedures. 1. Install switch to bezel. 2. Connect wire harness connector to switch. 3. Insert the front of the switch into the door trim panel first, then press into position. 4. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Description and Operation Power Window Circuit Breaker: Description and Operation An automatic resetting circuit breaker in the junction block is used to protect the power seat system circuit. The circuit breaker can protect the system from a short circuit, or from an overload condition caused by an obstructed or stuck seat adjuster. The circuit breaker cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Description and Operation > Page 7885 Power Window Circuit Breaker: Testing and Inspection 1. Locate the circuit breaker in the junction block. Pull out the circuit breaker slightly, but be certain that the circuit breaker terminals still contact the terminals in the junction block cavities. 2. Connect the negative lead of a 12-volt DC voltmeter to a good ground. 3. With the voltmeter positive lead, check both terminals of the circuit breaker for battery voltage. If only one terminal has battery voltage, the circuit breaker is faulty and must be replaced. If neither terminal has battery voltage, repair the open circuit from the Power Distribution Center (PDC) as required. If the circuit breaker checks OK, but no power windows operate, refer to ALL WINDOWS INOPERATIVE. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams Power Window Motor: Diagrams Driver Door Power Window Motor Left Rear Door Power Window Motor Passenger Door Power Window Motor Right Rear Door Power Window Motor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Page 7889 Power Window Motor: Description and Operation WINDOW MOTOR A permanent magnet reversible motor moves the window regulator through an integral gearbox mechanism. A positive and negative battery connection to the two motor terminals will cause the motor to rotate in one direction. Reversing the current through these same two connections will cause the motor to rotate in the opposite direction. In addition, each power window motor is equipped with an integral self-resetting circuit breaker to protect the motor from overloads. The power window motor and gearbox assembly cannot be repaired and, if faulty or damaged, the entire power window regulator assembly must be replaced. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Page 7890 Power Window Motor: Testing and Inspection 1. Disconnect and isolate the battery negative cable. Remove the trim panel from the door with the inoperative power window. 2. Unplug the power window motor wire harness connector. Apply 12 volts across the motor terminals to check its operation in one direction. Reverse the connections across the motor terminals to check the operation in the other direction. Remember, if the window is in the full up or full down position, the motor will not operate in that direction by design. If OK, repair the circuits from the power window motor to the power window switch as required. If not OK, replace the faulty motor. 3. If the motor operates in both directions, check the operation of the window glass and lift mechanism through its complete up and down travel. There should be no binding or sticking of the window glass or lift mechanism through the entire travel range. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Page 7891 Power Window Motor: Service and Repair REMOVAL The power window motor and mechanism is integral to the power window regulator unit. If the power window motor or mechanism is faulty or damaged, the entire power window regulator unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams Power Window Switch: Diagrams Left Rear Door Power Window Switch Passenger Door Power Window Switch Right Rear Door Power Window Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Page 7895 Power Window Switch: Description and Operation The power windows are controlled by two-way switches integral to the power window and lock switch and bezel unit on the trim panel of each front door. A second power window switch in the driver side switch and bezel unit allows the driver to control the passenger windows. The power window switch for the driver side front door window has an Auto label on it. This switch has a second detent position beyond the normal Down position that provides an automatic one-touch window down feature. This feature is controlled by an electronic circuit and a relay that are integral to the Driver Door Module. The power window switches control the battery and ground feeds to the power window motors. All of the passenger door power window switches receive their battery and ground feeds through the circuitry of the Driver Door Module. When the power window lockout switch is in the Lock position, the battery feed for the individual passenger door power window switches is interrupted. A Light-Emitting Diode (LED) in the paddle of each switch is illuminated whenever the ignition switch is in the ON position. However, the LEDs for the passenger power window switches are extinguished whenever the driver selects the Lock position with the power window lockout switch. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Page 7896 Power Window Switch: Testing and Inspection The Light-Emitting Diode (LED) illumination lamps for all of the power window and lock switch and bezel unit switch paddles receive battery current through the power window circuit breaker in the junction block. If all of the LEDs are inoperative in both the power window and lock switch units and the power windows are inoperative, (Refer to POWER WINDOWS - DIAGNOSIS AND TESTING). If the power windows operate, but any or all of the LEDs are inoperative, the power window and lock switch units with the inoperative LED(s) is faulty and must be replaced. 1. Check the circuit breaker in the junction block. If OK, go to Step 2. If not OK, replace the faulty circuit breaker. 2. Turn the ignition switch to the ON position. Check for battery voltage at the circuit breaker in the junction block. If OK, turn the ignition switch to the OFF position and go to Step 3. If not OK, repair the circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Remove the power window switch unit from the door trim panel (passenger doors). The drivers door switch is included with the Driver Door Module (Refer to POWER LOCKS/DOOR MODULE DIAGNOSIS AND TESTING) for service procedures. Unplug the wire harness connector from the switch unit, Passenger Door Switch 4. Test the power window switch continuity. See the Power Window Switch Continuity charts to determine if the continuity is correct in the OFF, Up and Down switch positions. If OK, (Refer to WINDOW MOTOR - DIAGNOSIS AND TESTING). If not OK, replace the faulty switch. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Page 7897 Power Window Switch: Service and Repair REMOVAL The driver side power window switch is included with the Drive Door Module. (Refer to POWER LOCKS/DOOR MODULE - REMOVAL) for the service procedures. 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick, start at the rear of the switch bezel and pry up from door trim panel 3. Disconnect the wire harness connector from switch. 4. Remove switch from bezel. INSTALLATION The driver side power window switch is included with the Drive Door Module. (Refer to POWER LOCKS/DOOR MODULE - INSTALLATION) for the service procedures. 1. Install switch to bezel. 2. Connect wire harness connector to switch. 3. Insert the front of the switch into the door trim panel first, then press into position. 4. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Inner Belt Weatherstrip Front Door Window Glass Weatherstrip: Service and Repair Front Door Inner Belt Weatherstrip FRONT DOOR INNER BELT WEATHERSTRIP REMOVAL 1. Remove trim panel. Fig. 2 2. Peel seal from door (Fig. 2). INSTALLATION 1. Slide seal into position on door. 2. Install the trim panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Inner Belt Weatherstrip > Page 7904 Front Door Window Glass Weatherstrip: Service and Repair Front Door Outer Belt Weatherstrip FRONT DOOR OUTER BELT WEATHERSTRIP REMOVAL 1. Lower glass. Fig. 2 2. Lift rearward corner of weatherstrip and slide weatherstrip rearward (Fig. 2). INSTALLATION 1. Lightly lubricate weatherstrip with silicone and slide weatherstrip behind mirror. 2. Push weatherstrip down to seat onto door. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Inner Belt Weatherstrip > Page 7905 Front Door Window Glass Weatherstrip: Service and Repair Front Door Glass Run Weatherstrip FRONT DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove glass. Fig. 2 2. Pull the glass run weatherstrip and run channels from the window opening (Fig. 2). 3. Pull the glass run weatherstrip from the run channels. INSTALLATION 1. Install the glass run weatherstrip in the run channels. 2. Install the glass run weatherstrip in the window opening. 3. Position the run channels in the door. 4. Install glass. 5. Install door trim panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Inner Belt Weatherstrip > Page 7906 Front Door Window Glass Weatherstrip: Service and Repair Glass Run Channel GLASS RUN CHANNEL REMOVAL 1. Remove trim panel. 2. Remove water dam as necessary to access lower run channels. Fig. 5 3. Remove bolts attaching lower glass run channels to door panel (Fig. 5). 4. Remove glass. 5. Slide lower run channels downward to disengage from upper run channels. 6. Remove lower run channels from door. INSTALLATI0N 1. Position lower run channels in door. 2. Slide lower run channels upward to engage in to upper run channels. 3. Install glass. 4. Install bolts attaching lower glass run channels to door panel. 5. Install water dam. 6. Install trim panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair Liftgate Window Glass: Service and Repair BACKLITE REMOVAL 1. Remove liftgate upper trim panel. 2. Remove center high mounted stop lamp. 3. Remove rear window wiper arm, if equipped. 4. Remove side moldings. 5. Cut urethane bonding from around liftgate backlite using a suitable sharp cold knife. A pneumatic cutting device can be used if available. 6. Separate backlite from vehicle. INSTALLATION CAUTION: Open a window before installing backlite. This will avoid pressurizing the passenger compartment. If a door is slammed before urethane is cured, water leaks can result. The window opening fence should be cleaned of old urethane bonding material. 1. Clean inside of backlite with Mopar(R) Glass Cleaner or equivalent and lint-free cloth. 2. Apply PVC (vinyl) primer 25 mm (1 in.) wide around edge of backlite. Wipe with clean/dry lint-free cloth. 3. Apply fence primer around edge of fence. Allow at least eighteen minutes drying time. Fig. 8 4. Install new upper and lower seals on liftgate backlite (Fig. 8). 5. Apply a 12 mm (0.4 in.) bead of urethane around window opening fence. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Page 7910 Fig. 9 6. Position backlite into window opening (Fig. 9). 7. Install the side moldings. 8. Install the rear wiper arm, if equipped. 9. Install the center high mounted stop lamp. 10. Install the liftgate upper trim panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair Quarter Window Glass: Service and Repair QUARTER WINDOW REMOVAL 1. Remove quarter panel trim. 2. Carefully pull down headliner to access upper nuts attaching quarter window glass to pinchweld and remove nuts. Fig. 7 3. Remove nuts attaching quarter window glass to pinchweld (Fig. 7). 4. Using razor knife, cut butyl sealer between the mounting studs attaching glass to pinchweld. 5. Push glass from opening. INSTALLATION NOTE: The pinchweld should be cleaned of all old butyl sealer. 1. Apply 6 mm (0.25 in.) of butyl tape around perimeter of glass assembly encapsulation track. Ensure the butyl tape is wrapped around the mounting studs. 2. Place glass into opening and insert mounting studs through holes in pinchweld. 3. Install nuts attaching quarter window glass to pinchweld and tighten to 4.5 N.m (40 in. lbs.). 4. Install quarter panel trim. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel Rear Door Window Glass Weatherstrip: Service and Repair Glass Run Channel GLASS RUN CHANNEL REMOVAL 1. Remove waterdam. Refer to Rear Door Panel. Fig. 4 2. Ensure glass is in full up position and supported. Remove bolts attaching the run channels to door inner panel (Fig. 4). 3. Remove speaker, if necessary. 4. Separate run channels from door. INSTALLATION 1. Position run channels in door. 2. Install bolts attaching the run channels to door inner panel (Fig. 4). 3. Install speaker, if necessary. 4. Install waterdam. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 7919 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Inner Belt Weatherstrip REAR DOOR INNER BELT WEATHERSTRIP REMOVAL 1. Remove trim panel. Fig. 6 2. Pull weatherstrip from inner door panel (Fig. 6). INSTALLATION 1. Position weatherstrip on inner door panel (Fig. 6). 2. Press into place. 3. Install trim panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 7920 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Glass Run Weatherstrip REAR DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove trim panel. 2. Remove inner belt weatherstrip. 3. Remove outer beltline weatherstrip. Fig. 5 4. Pull weatherstrip from door frame and divider bar channel (Fig. 5). INSTALLATION 1. Position weatherstrip in door frame and divider bar channel. 2. Install outer beltline weatherstrip. 3. Install inner beltline weatherstrip. 4. Install trim panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 7921 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Outer Belt Weatherstrip REAR DOOR OUTER BELT WEATHERSTRIP REMOVAL 1. Lower glass. Fig. 6 2. Lift corner of weatherstrip upward and remove weatherstrip from outer door panel (Fig. 6). INSTALLATION 1. Position weatherstrip on outer door panel (Fig. 6). 2. Press into place. 3. Raise glass. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Procedures Front Door Window Regulator: Procedures FRONT DOOR WINDOW REGULATOR REMOVAL 1. Remove door trim panel. 2. Partially remove waterdam. 3. Position glass to access the fasteners. Remove the fasteners. 4. Disengage glass from regulator lift channel. 5. Position glass up into door frame (rest glass on a block of wood on door reinforcement). 6. Disconnect regulator wire harness. Fig. 38 Front Door Window Regulator Fig. 39 Power Regulator Bolts 7. Remove screws attaching window regulator to door inner panel. 8. Remove window regulator from door. INSTALLATION Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 7927 1. Position window regulator in door. 2. Loosely install screws attaching window regulator to door inner panel. 3. Position glass onto window regulator lift channel. 4. Install glass to lift channel fasteners. 5. Cycle the window glass to the full up position. 6. Tighten bolts attaching lower front glass run channel to door inner panel. 7. Tighten fasteners holding window regulator to door inner panel. 8. Connect regulator wire harness, if equipped. 9. Install waterdam. 10. Install door trim panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 7928 Front Door Window Regulator: Removal and Replacement WINDOW REGULATOR REMOVAL 1. Remove door trim panel. 2. Partially remove waterdam. 3. Position glass to access the fasteners. Remove the fasteners. 4. Disengage glass from regulator lift channel. 5. Position glass up into door frame (rest glass on a block of wood on door reinforcement). 6. Disconnect regulator wire harness. Fig. 17 Fig. 18 7. Remove screws attaching window regulator to door inner panel (Fig. 17) and (Fig. 18). 8. Remove window regulator from door. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 7929 INSTALLATI0N 1. Position window regulator in door. 2. Loosely install screws attaching window regulator to door inner panel. 3. Position glass onto window regulator lift channel. 4. Install glass to lift channel fasteners. 5. Cycle the window glass to the full up position. 6. Tighten bolts attaching lower front glass run channel to door inner panel. 7. Tighten fasteners holding window regulator door inner panel. 8. Connect regulator wire harness, if equipped. 9. Install waterdam. 10. Install door trim panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Procedures Rear Door Window Regulator: Procedures REAR DOOR WINDOW REGULATOR REMOVAL 1. Remove upper door trim extension panel. 2. Remove door trim panel. 3. Position glass to access the fasteners. Remove the fasteners. 4. Disengage glass from regulator lift channel. 5. Position glass up into door frame (rest glass on a block of wood on door reinforcement). 6. Lower waterdam. 7. Disconnect regulator wire harness, if equipped. Fig. 55 Rear Door Window Regulator - Manual Fig. 56 Rear Door Window Regulator - Power 8. Remove screws attaching window regulator to door inner panel. 9. Remove window regulator from door. INSTALLATION 1. Position window regulator in door. 2. Loosely install screws attaching window regulator to door inner panel. 3. Install glass onto regulator lift channel. Secure fasteners. 4. Connect regulator wire harness, if equipped. 5. Cycle the window glass to the full up position. 6. Tighten bolts attaching the regulator to the inner door panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 7934 7. Install waterdam. 8. Install door trim panel. 9. Install upper door trim extension panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 7935 Rear Door Window Regulator: Removal and Replacement WINDOW REGULATOR REMOVAL 1. Remove upper door trim extension panel. 2. Remove door trim panel. 3. Position glass to access the fasteners. Remove the fasteners. 4. Disengage glass from regulator lift channel. 5. Position glass up into door frame (rest glass on a block of wood on door reinforcement). 6. Lower waterdam. 7. Disconnect regulator wire harness, if equipped. Fig. 13 Fig. 14 8. Remove screws attaching window regulator to door inner panel (Fig. 13) and (Fig. 14). 9. Remove window regulator from door. INSTALLATION 1. Position window regulator in door. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 7936 2. Loosely install screws attaching window regulator to door inner panel. 3. Install glass onto regulator lift channel. Secure fasteners. 4. Connect regulator wire harness, if equipped. 5. Cycle the window glass to the full up position. 6. Tighten bolts attaching the regulator to the inner door panel. 7. Install waterdam. 8. Install door trim panel. 9. Install upper door trim extension panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions Windshield: Service Precautions WINDSHIELD SAFETY PRECAUTIONS WARNING: - DO NOT OPERATE THE VEHICLE WITHIN 24 HOURS OF WINDSHIELD INSTALLATION. IT TAKES AT LEAST 24 HOURS FOR URETHANE ADHESIVE TO CURE. IF IT IS NOT CURED, THE WINDSHIELD MAY NOT PERFORM PROPERLY IN AN ACCIDENT. - URETHANE ADHESIVES ARE APPLIED AS A SYSTEM. USE GLASS CLEANER, GLASS PREP SOLVENT, GLASS PRIMER, PVC (VINYL) PRIMER AND PINCH WELD (FENCE) PRIMER PROVIDED BY THE ADHESIVE MANUFACTURER. IF NOT, STRUCTURAL INTEGRITY COULD BE COMPROMISED. - DAIMLERCHRYSLER DOES NOT RECOMMEND GLASS ADHESIVE BY BRAND. TECHNICIANS SHOULD REVIEW PRODUCT LABELS AND TECHNICAL DATA SHEETS, AND USE ONLY ADHESIVES THAT THEIR MANUFACTURES WARRANT WILL RESTORE A VEHICLE TO THE REQUIREMENTS OF FMVSS 212. TECHNICIANS SHOULD ALSO INSURE THAT PRIMERS AND CLEANERS ARE COMPATIBLE WITH THE PARTICULAR ADHESIVE USED. - BE SURE TO REFER TO THE URETHANE MANUFACTURERS DIRECTIONS FOR CURING TIME SPECIFICATIONS, AND DO NOT USE ADHESIVE AFTER ITS EXPIRATION DATE. - VAPORS THAT ARE EMITTED FROM THE URETHANE ADHESIVE OR PRIMER COULD CAUSE PERSONAL INJURY. USE THEM IN A WELL-VENTILATED AREA. - SKIN CONTACT WITH URETHANE ADHESIVE SHOULD BE AVOIDED. PERSONAL INJURY MAY RESULT. - ALWAYS WEAR EYE AND HAND PROTECTION WHEN WORKING WITH GLASS. CAUTION: Protect all painted and trimmed surfaces from coming in contact with urethane or primers. Be careful not to damage painted surfaces when removing moldings or cutting urethane around windshield. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 7940 Windshield: Service and Repair WINDSHIELD REMOVAL 1. Remove rear view mirror. 2. Remove wiper arms and cowl grille. 3. With doors open, remove the weatherstrip from the side windshield moldings. 4. Remove the screws attaching the side windshield molding to the A-pillars. Fig. 1 5. Cut urethane bonding from around windshield using a suitable sharp cold knife (Fig. 1). 6. Using a long knife, cut urethane bonding from inside the cab at the base of the windshield. INSTALLATION WARNING: ALLOW THE URETHANE AT LEAST 24 HOURS TO CURE BEFORE RETURNING THE VEHICLE TO USE. CAUTION: Roll down the left and right front door glass and open the rear glass slider (if available) before installing windshield to avoid pressurizing the passenger compartment if a door is slammed before urethane is cured. Water leaks can result. Fig. 2 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 7941 NOTE: The windshield fence should be cleaned of most of its old urethane bonding material. A small amount of old urethane, approximately 1-2 mm in height, should remain on the fence. Do not grind off or completely remove all old urethane from the fence, the paint finish and bonding strength will be adversely affected. Support spacers located on the cowl at the bottom of the windshield opening (Fig. 2) should be replaced with new parts. Replace any missing or damaged spacers around the perimeter of the windshield opening. Fig. 3 1. Place replacement windshield into windshield opening and position glass in the center of the opening against the support spacers. Mark the glass at the support spacers with a grease pencil or pieces of masking tape and ink pen to use as a reference for installation. Remove replacement windshield from windshield opening (Fig. 3). Fig. 4 2. Position the windshield inside up on a suitable work surface with two padded, wood 10 cm by 10 cm by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed parallel 75 cm (2.5 ft.) apart (Fig. 4). 3. Clean inside of windshield with MOPAR(R) Glass Cleaner and lint-free cloth. 4. Apply clear glass primer 25 mm (1 in.) wide around perimeter of windshield and wipe with a new clean and dry lint-free cloth. 5. Apply pinchweld primer 15 mm (.75 in.) wide around the windshield fence. Allow at least three minutes drying time. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 7942 Fig. 5 6. Apply a 13 mm (l/2 in.) high and 10 mm (3/8 in.) wide bead of urethane around the perimeter of windshield. At the bottom, apply the bead 7 mm (1/4 in.) inboard from the glass edge. On the three sides where the molding is on the glass, follow the edge of molding. The urethane bead should be shaped in a triangular cross-section, this can be achieved by notching the tip of the applicator (Fig. 5). 7. With the aid of a helper, position the windshield over the windshield opening. Align the reference marks at the bottom of the windshield to the support spacers. 8. Slowly lower windshield glass to the fence opening guiding the lower corners into proper position. Beginning at the bottom and continuing to the top, push glass onto fence along the A-Pillars. Push windshield inward to the fence at the bottom corners. 9. Clean excess urethane from exterior with MOPAR(R) Super Clean or equivalent. 10. Apply 150 mm (6 in.) lengths of 50 mm (2 in.) masking tape spaced 250 mm (10 in.) apart to hold molding in place until urethane cures. 11. Install new screws attaching the side windshield moldings to the A-pillars. 12. Install the weatherstrip onto side windshield moldings. 13. Install cowl grille. 14. Install the wiper arms. 15. Install the rear view mirror bracket. 16. Install rear view mirror. 17. After urethane has cured, remove tape strips and water test windshield to verify repair. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Service and Repair > Front Check Valve Replacement Check Valve: Service and Repair Front Check Valve Replacement REMOVAL 1. Remove the front wiper arms from the wiper pivots. (Refer to FRONT WIPER ARMS REMOVAL). 2. Open the hood and pull the hood to plenum seal off of the forward flanges of the cowl grille cover and the plenum panel. 3. Remove the cowl plenum cover/grille panel from the top of the cowl plenum. 4. From the underside of the cowl plenum coven grille panel, disconnect the washer hoses from the three barbed nipples of the eye fitting/check valve unit. 5. Remove the eye fitting/check valve unit from the underside of the cowl plenum cover/grille panel. INSTALLATION 1. Position the eye fitting/check valve unit to the underside of the cowl plenum cover/grille panel. 2. From the underside of the cowl plenum cover/grille panel, reconnect the three washer hoses to the barbed nipples of the eye fitting/check valve unit. 3. Reinstall the washer hoses for the front washer nozzles into their locating clips on the underside of the cowl plenum cover/grille panel. 4. Reinstall the cowl plenum cover/grille panel onto the top of the cowl plenum panel. 5. Reinstall the front wiper arms onto the wiper pivots. (Refer to FRONT WIPER ARMS - INSTALLATION). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Service and Repair > Front Check Valve Replacement > Page 7948 Check Valve: Service and Repair Rear Check Valve Replacement REMOVAL 1. Unlatch and open the hood. 2. Locate the connection between the rear washer system engine compartment supply hose and passenger compartment supply hose sections. This connection can be found just behind the air cleaner housing on the top of the right front fender wheel house, where the front and rear washer system hoses are routed near the headlamp and dash wire harness. 3. Disconnect the passenger compartment half of the washer supply hose from the barbed nipple on the rear washer system check valve. A small quantity of washer fluid will drain from the disconnected hose. 4. Disconnect the engine compartment half of the washer supply hose from the other barbed nipple of the rear check valve. Either install a temporary plug in the engine compartment half of the supply hose or secure the loose end of this hose at a point higher than the washer reservoir to prevent the contents of the washer reservoir from draining through this hose. 5. Remove the rear check valve from the engine compartment. INSTALLATION 1. Position the rear check valve onto the back of the right front wheel house in the engine compartment. Fig.3 Rear Check Valve 2. With the tapered end of the check valve pointed in the direction of the system flow, reconnect the engine compartment half of the washer supply hose to the barbed nipple of the rear check valve. 3. Reconnect the passenger compartment half of the washer supply hose to the other barbed nipple of the rear check valve. 4. Check that the washer supply hose are properly routed and are not pinched. 5. Close and latch the hood. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Description and Operation Wiper Control Module: Description and Operation FRONT WIPER MODULE The wiper module is secured with screws through four rubber grommet-type insulators to the cowl plenum panel and concealed within the cowl plenum area beneath the cowl plenum cover/grille panel. The ends of the wiper pivot shafts that protrude through dedicated openings in the cowl plenum cover/grille panel to drive the wiper arms and blades are the only visible components of the wiper module. The wiper module consists of the following major components: Bracket - The wiper module bracket consists of a long tubular steel main member that has a stamped pivot bracket formation near each end where the two wiper pivots are secured. A stamped steel mounting plate for the wiper motor is secured with welds near the center of the main member. - Crank Arm - The wiper motor crank arm is a stamped steel unit that has a slotted hole on the driven end that is secured to the wiper motor output shaft with a nut, and has a ball stud secured to the drive end. - Linkage - The two wiper linkage members are each constructed of stamped steel. A driver side drive link with a plastic socket-type bushing in the left end, and a plastic sleeve-type bushing in the right end. Socket bushing is snap-fit over the pivot ball stud on the left pivot, while the sleeve bushing is fit over the longer wiper motor crank arm pivot stud. The passenger side drive link has a plastic socket-type bushing on each end. One end of this drive link is snap-fit over the pivot ball stud on the right pivot, while the other end is snap-fit over the exposed end of the longer ball stud on the wiper motor crank arm. - Motor - The wiper motor is secured with three screws to the motor mounting plate near the center of the wiper module bracket. The wiper motor output shaft passes through a hole in the module bracket, where a nut secures the wiper motor crank arm to the motor output shaft. The two-speed permanent magnet wiper motor features an integral transmission, an internal park switch, and an internal Positive Temperature Coefficient (PTC) circuit breaker. - Pivots - The two wiper pivots are secured to the ends of the wiper module bracket. The crank arms that extend from the bottom of the pivot shafts each have a ball stud on their end. The upper end of each pivot shaft where the wiper arms will be fastened each has an externally serrated drum secured to it. The wiper module cannot be adjusted or repaired. If any component of the module is faulty or damaged, the entire wiper module unit must be replaced. The wiper module operation is controlled by the vehicle operator through battery current inputs received by the wiper motor from the multi-function switch on the steering column. The wiper motor speed is controlled by current flow to either the low speed or the high speed set of brushes. The park switch is a single pole, single throw, momentary switch within the wiper motor that is mechanically actuated by the wiper motor transmission components. The park switch alternately closes the wiper park switch sense circuit to ground or to battery current, depending upon the position of the wipers on the glass. This feature allows the motor to complete its current wipe cycle after the wiper system has been turned OFF, and to park the wiper blades in the lowest portion of the wipe pattern. The automatic resetting circuit breaker protects the motor from overloads. The wiper motor crank arm, the two wiper linkage members, and the two wiper pivots mechanically convert the rotary output of the wiper motor to the back and forth wiping motion of the wiper arms and blades on the glass. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Description and Operation > Page 7953 Wiper Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the front wiper arms from the wiper pivots. (Refer to FRONT WIPER ARMS - REMOVAL). 3. Remove the cowl plenum cover/grille panel from the cowl plenum. Fig.11 Wiper Module Removal/Install 4. Remove the four screws that secure the front wiper module bracket to the cowl plenum panel and the dash panel. 5. Reach into the cowl plenum to move the front wiper module far enough to access the wiper module electrical connections. 6. Disconnect the headlamp and dash wire harness connector for the front wiper motor from the wiper motor pigtail wire connector. 7. Disconnect the headlamp and dash wire harness ground connector from the front wiper motor ground terminal. 8. Remove the front wiper module from the cowl plenum as a unit. INSTALLATION 1. Position the front wiper module into the cowl plenum as a unit. 2. Reconnect the headlamp and dash wire harness ground connector to the front wiper motor ground terminal. 3. Reconnect the headlamp and dash wire harness connector for the front wiper motor to the wiper motor pigtail wire connector. 4. Reach into the cowl plenum to align the front wiper module mounting bracket with the locations for the mounting screws. 5. Install and tighten the four screws that secure the front wiper module bracket to the cowl plenum panel and the dash panel. Tighten the screws to 8 Nm (72 in. lbs.). 6. Reinstall the cowl plenum cover/grille panel over the top of the cowl plenum. 7. Reinstall the front wiper arms onto the wiper pivots. (Refer to FRONT WIPER ARMS - INSTALLATION). 8. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Power Distribution Center Wiper Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7957 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7958 Wiper Relay: Diagrams Front Wiper Motor Relay Rear Wiper Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7959 Wiper Relay: Description and Operation FRONT WIPER RELAY The front wiper relay (or intermittent wipe relay) is located in the Power Distribution Center (PDC) near the battery in the engine compartment. See the fuse and relay layout label affixed to the inside surface of the PDC cover for front wiper relay identification and location. The front wiper relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The relay is contained within a small, rectangular, molded plastic housing. The relay is connected to all of the required inputs and outputs through its PDC receptacle by five male spade-type terminals that extend from the bottom of the relay base. The ISO designation for each terminal is molded into the base adjacent to the terminal. The ISO terminal designations are as follows: 30 (Common Feed) - This terminal is connected to the movable contact point of the relay. - 85 (Coil Ground) - This terminal is connected to the ground feed side of the relay control coil. - 86 (Coil Battery) - This terminal is connected to the battery feed side of the relay control coil. - 87 (Normally Open) - This terminal is connected to the normally open fixed contact point of the relay. - 87A (Normally Closed) - This terminal is connected to the normally closed fixed contact point of the relay. The front wiper relay cannot be adjusted or repaired. If the relay is damaged or faulty, it must be replaced. The front wiper relay (or intermittent wipe relay) is an electromechanical switch that uses a low current input from the Central Timer Module ( CTM) to control a high current output to the low speed brush of the front wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor or diode is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The front wiper relay terminals are connected to the vehicle electrical system through a connector receptacle in the Power Distribution Center (PDC). The inputs and outputs of the front wiper relay include: The common feed terminal (30) is connected to the front wiper motor low speed brush through the wiper control circuitry of the multi-function switch on the steering column. When the front wiper relay is de-energized, the common feed terminal is connected to the front wiper park switch output through the CTM on the front wiper park switch sense circuit. The front wiper park switch output may be battery current (wipers are not parked), or ground (wipers are parked). When the front wiper relay is energized, the common feed terminal of the relay is connected to battery current from a fuse in the Junction Block (JB) through a fused ignition switch output (run-acc) circuit. - The coil ground terminal (85) is connected to the relay control output of the CTM through the wiper relay control circuit. The CTM controls the ground path for this circuit internally to energize or de-energize the front wiper relay based upon its programming, inputs from the front wiper and washer control circuitry of the multi-function switch, and inputs from the front wiper motor park switch. The coil battery terminal (86) is connected to battery current from a fuse in the Junction Block (JB) through a fused ignition switch output (run-acc) circuit whenever the ignition switch is in the ON or Accessory positions. - The normally open terminal (87) is connected to battery current from a fuse in the Junction Block (JB) through a fused ignition switch output (run-acc) circuit whenever the front wiper relay control coil is energized by the CTM. This circuit provides fused ignition switch output (run-acc) current to the front wiper motor low speed brush only when the front wiper relay control coil is energized. - The normally closed terminal (87A) is connected to the output of the front wiper motor park switch through the CTM on the front wiper park switch sense circuit. This circuit provides battery current (wipers are not parked) or ground (wipers are parked) to the front wiper motor low speed brush whenever the front wiper relay control coil is de-energized and the OFF position of the front wiper control circuitry within the multi-function switch is selected. The front wiper relay can be diagnosed using conventional diagnostic tools and methods. REAR WIPER RELAY The rear wiper relay is located in the Power Distribution Center (PDC) near the battery in the engine compartment. See the fuse and relay layout label affixed to the inside surface of the PDC cover for rear wiper relay identification and location. The rear wiper relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The relay is contained within a small, rectangular, molded plastic housing. The relay is connected to all of the required inputs and outputs through its PDC receptacle by five male spade-type terminals that extend from the bottom of the relay base. The ISO designation for each terminal is molded into the base adjacent to the terminal. The ISO terminal designations are as follows: 30 (Common Feed) - This terminal is connected to the movable contact point of the relay. - 85 (Coil Ground) - This terminal is connected to the ground feed side of the relay control coil. - 86 (Coil Battery) - This terminal is connected to the battery feed side of the relay control coil. - 87 (Normally Open) - This terminal is connected to the normally open fixed contact point of the relay. - 87A (Normally Closed) - This terminal is connected to the normally closed fixed contact point of the relay. The rear wiper relay cannot be adjusted or repaired. If the relay is damaged or faulty, it must be replaced. The rear wiper relay is an electromechanical switch that uses a low current input from the Central Timer Module (CTM) to control a high current output to the rear wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7960 contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor or diode is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The rear wiper relay terminals are connected to the vehicle electrical system through a connector receptacle in the Power Distribution Center (PDC). The inputs and outputs of the rear wiper relay include: - The common feed terminal (30) is connected to the rear wiper motor through the rear wiper motor control circuit to the rear wiper motor. When the rear wiper relay is de-energized, the common feed terminal is connected to ground through a take out and eyelet terminal connector of the headlamp and dash wire harness that is secured by a nut to a ground stud located on the left front fender inner shield in the engine compartment near the battery. When the rear wiper relay is energized, the common feed terminal of the relay is connected to battery current from a fuse in the Power Distribution Center (PDC) through a fused B(+) circuit. - The coil ground terminal (85) is connected to the relay control output of the CTM through the rear wiper relay control circuit. The CTM controls the ground path for this circuit internally to energize or de-energize the rear wiper relay based upon its programming, electronic wiper and washer switch state message inputs from the heater-air conditioner control, and a hard wired input from the rear wiper motor park switch. - The coil battery terminal (86) is connected to battery current from a fuse in the PDC through a fused B(+) circuit at all times. - The normally open terminal (87) is connected to battery current from a fuse in the PDC through a fused B(+) circuit at all times. - The normally closed terminal (87A) is connected to ground through a take out and eyelet terminal connector of the headlamp and dash wire harness that is secured by a nut to a ground stud located on the left front fender inner shield in the engine compartment near the battery. The rear wiper relay can be diagnosed using conventional diagnostic tools and methods. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Front Wiper Relay Test Wiper Relay: Testing and Inspection Front Wiper Relay Test Fig. 9 Front Wiper Relay The front wiper relay (or intermittent wipe relay) is located in the Power Distribution Center (PDC) in the engine compartment. See the fuse and relay layout label affixed to the inside surface of the PDC cover for front wiper relay identification and location. 1. Remove the front wiper relay from the PDC. (Refer to FRONT WIPER RELAY - REMOVAL). 2. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 4. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, test the relay input and output circuits. Refer to RELAY CIRCUIT TEST . If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to the multi-function switch. There should be continuity between the receptacle for terminal 30 of the front wiper relay in the PDC and the intermittent front wiper low speed circuit cavity of the instrument panel wire harness connector for the multi-function switch at all times. If OK, go to Step 2. If not OK, repair the open intermittent front wiper low speed circuit between the PDC and the multi-function switch as required. 2. The relay normally closed terminal (87A) is connected to the front wiper motor park switch through the CTM on the front wiper park switch sense circuit. There should be continuity between the receptacle for terminal 87A of the front wiper relay in the PDC and the front wiper park switch sense circuit cavity of the headlamp and dash wire harness connector for the wiper motor at all times. If OK, go to Step 3. If not OK, repair the open front wiper park switch sense circuit between the PDC and the front wiper motor as required. 3. The relay normally open terminal (87) is connected to a fused ignition switch output (run-acc) fuse in the Junction Block (JB) through a fused ignition switch output (run-acc) circuit. There should be battery voltage at the receptacle for terminal 87 of the front wiper relay in the PDC whenever the ignition switch is in the ON or Accessory positions. If OK, go to Step 4. If not OK, repair the open fused ignition switch output (run-acc) circuit between the PDC and the JB as required. 4. The coil battery terminal (86) is connected to a fused ignition switch output (run-acc) fuse in the JB through a fused ignition switch output (run-acc) circuit. There should be battery voltage at the receptacle for terminal 86 of the front wiper relay in the PDC whenever the ignition switch is in the ON or Accessory positions. If OK, go to Step 5. If not OK, repair the open fused ignition switch output (run-acc) circuit between the PDC and the JB as required. 5. The coil ground terminal (85) is connected to the output of the Central Timer Module (CTM) through the wiper relay control circuit. There should be continuity between the receptacle for terminal 85 of the front wiper relay in the PDC and the wiper relay control circuit cavity of the instrument panel wire harness connector (Connector C3) for the CTM at all times. If not OK, repair the open wiper relay control circuit between the PDC and the CTM as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Front Wiper Relay Test > Page 7963 Wiper Relay: Testing and Inspection Rear Wiper Relay Test Fig. 14 Rear Wiper Relay The rear wiper relay is located in the Power Distribution Center (PDC) in the engine compartment. See the fuse and relay layout label affixed to the inside surface of the PDC cover for rear wiper relay identification and location. 1. Remove the rear wiper relay from the PDC. (Refer to REAR WIPER RELAY - REMOVAL). 2. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 4. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, test the relay input and output circuits. Refer to RELAY CIRCUIT TEST. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to the multi-function switch. There should be continuity between the receptacle for terminal 30 of the rear wiper relay in the PDC and the rear wiper motor control circuit cavity of the liftgate wire harness connector for the rear wiper motor at all times. If OK, go to Step 2. If not OK, repair the open rear wiper motor control circuit between the PDC and the rear wiper motor as required. 2. The relay normally closed terminal (87A) is connected to ground. There should be continuity between the receptacle for terminal 87A of the rear wiper relay in the PDC and a good ground at all times. If OK, go to Step 3. If not OK, repair the open ground circuit to ground (G113) as required. 3. The relay normally open terminal (87) is connected to a fused B(+) fuse in the PDC through a fused B(+) circuit. There should be battery voltage at the receptacle for terminal 87 of the rear wiper relay at all times. If OK, go to Step 4. If not OK, repair the open B(+) circuit between the PDC and the battery as required. 4. The coil battery terminal (86) is connected to a fused B(+) fuse in the PDC through a fused B(+) circuit. There should be battery voltage at the receptacle for terminal 86 of the rear wiper relay at all times. If OK, go to Step 5. If not OK, repair the open B(+) circuit between the PDC and the battery as required. 5. The coil ground terminal (85) is connected to the output of the Central Timer Module (CTM) through the rear wiper relay control circuit. There should be continuity between the receptacle for terminal 85 of the rear wiper relay in the PDC and the rear wiper relay control circuit cavity of the instrument panel wire harness connector (Connector C3) for the CTM at all times. If not OK, repair the open rear wiper relay control circuit between the PDC and the CTM as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Service and Repair > Front Wiper Relay Replacement Wiper Relay: Service and Repair Front Wiper Relay Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. Fig. 10 Power Distribution Center - Typical 2. Remove the cover from the Power Distribution Center (PDC). 3. See the fuse and relay layout label affixed to the underside of the PDC cover for front wiper relay identification and location. 4. Remove the front wiper relay by grasping it firmly and pulling it straight out from the receptacle in the PDC. INSTALLATION 1. See the fuse and relay layout label affixed to the underside of the PDC cover for the proper front wiper relay location. 2. Position the front wiper relay in the proper receptacle in the PDC. 3. Align the front wiper relay terminals with the terminal cavities in the PDC receptacle. 4. Push firmly and evenly on the top of the front wiper relay until the terminals are fully seated in the terminal cavities in the PDC receptacle. 5. Reinstall the cover onto the PDC. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Service and Repair > Front Wiper Relay Replacement > Page 7966 Wiper Relay: Service and Repair Rear Wiper Relay Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. Fig. 15 Power Distribution Center - Typical 2. Remove the cover from the Power Distribution Center (PDC) . 3. See the fuse and relay layout label affixed to the underside of the PDC cover for rear wiper relay identification and location. 4. Remove the rear wiper relay by grasping it firmly and pulling it straight out from the receptacle in the PDC. Fig. 10 Rear Wiper Blade INSTALLATION 1. See the fuse and relay layout label affixed to the underside of the PDC cover for the proper rear wiper relay location. 2. Position the rear wiper relay in the proper receptacle in the PDC. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Service and Repair > Front Wiper Relay Replacement > Page 7967 3. Align the rear wiper relay terminals with the terminal cavities in the PDC receptacle. 4. Push firmly and evenly on the top of the rear wiper relay until the terminals are fully seated in the terminal cavities in the PDC receptacle. 5. Reinstall the cover onto the PDC. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Washer Fluid Level Switch: Locations The washer fluid level switch is a single pole, single throw reed-type switch mounted on the outboard side of the washer reservoir forward of the two washer pump/motors, in the right front corner of the engine compartment. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7972 Washer Fluid Level Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7973 Washer Fluid Level Switch: Description and Operation The washer fluid level switch is a single pole, single throw reed-type switch mounted on the outboard side of the washer reservoir forward of the two washer pump/motors, in the right front corner of the engine compartment. Only the molded plastic switch mounting flange and connector receptacle are visible when the switch is installed in the reservoir. A short nipple formation extends from the inner surface of the switch mounting flange, and a barb on the nipple near the switch mounting flange is press-fit into a rubber grommet seal installed in the mounting hole of the reservoir. A small plastic float pivots on the end of a bracket that extends from the switch nipple formation. Within the float is a small magnet, which actuates the reed switch. The washer fluid level switch cannot be adjusted or repaired. If faulty or damaged, the switch must be replaced. The washer fluid level switch uses a pivoting, oblong float to monitor the level of the washer fluid in the washer reservoir. The float contains a small magnet. When the float pivots, the changing proximity of its magnetic field will cause the contacts of the small, stationary reed switch to open or close. When the fluid level in the washer reservoir is at or above the float level, the float moves to a vertical position and the switch contacts open. When the fluid level in the washer reservoir falls below the pivoting float, the float moves to a horizontal position and the switch contacts close. The switch contacts are connected in series between ground and the washer fluid switch sense input of the instrument cluster. The switch is connected to the vehicle electrical system through a dedicated take out and connector of the headlamp and dash wire harness. The switch receives ground through another take out of the headlamp and dash wire harness with a single eyelet terminal connector that is secured under a nut to a ground stud located on the right front fender inner shield in the engine compartment. The washer fluid level switch can be diagnosed using conventional diagnostic tools and methods. (Refer to WASHER FLUID INDICATOR - DIAGNOSIS AND TESTING). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7974 Washer Fluid Level Switch: Service and Repair REMOVAL The washer fluid level switch can be removed from the washer reservoir without removing the reservoir from the vehicle. 1. Disconnect and isolate the battery negative cable. 2. Disconnect the washer hose from the barbed outlet nipple of the washer pump/motor unit and allow the washer fluid to drain into a clean container for reuse. Fig. 11 Washer Fluid Level Switch 3. Disconnect the headlamp and dash wire harness connector for the washer fluid level switch from the switch connector receptacle. NOTE: The pivoting float of the washer fluid level switch must be in a horizontal position within the reservoir in order to be removed. With the reservoir empty and in an upright position, the pivoting float will orient itself to the horizontal position when the switch connector receptacle is pointed straight downwards. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed nipple of the washer fluid level switch out of the rubber grommet seal on the outboard side of the reservoir. Care must be taken not to damage the reservoir. 5. Remove the washer fluid level switch and float from the washer reservoir. 6. Remove the rubber grommet seal from the washer fluid level switch mounting hole in the washer reservoir and discard. INSTALLATION 1. Install a new rubber grommet seal into the washer fluid level switch mounting hole in the outboard side of the washer reservoir. Always use a new rubber grommet seal on the reservoir. 2. Position the float of the washer fluid level switch through the rubber grommet seal in the washer reservoir. The connector receptacle of the washer fluid level switch should be pointed downward. 3. Press firmly and evenly on the washer fluid level switch using hand pressure until the barbed nipple is fully seated in the rubber grommet seal in the washer reservoir mounting hole. 4. Reconnect the headlamp and dash wire harness connector for the washer fluid level switch to the switch connector receptacle. 5. Reconnect the washer hose to the barbed outlet nipple of the washer pump/motor unit. 6. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Locations Washer Fluid Level Indicator: Locations The washer fluid indicator is located in the Information Center area of the instrument cluster to the right of center. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Locations > Page 7978 Washer Fluid Level Indicator: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Locations > Page 7979 Washer Fluid Level Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the chart below. Damage to the lamp can result. Bulb Application Low Washer Fluid ................................................................................................................................ .............................................................. PC194 Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Locations > Page 7980 Washer Fluid Level Indicator: Description and Operation A washer fluid indicator is standard equipment on all instrument clusters. The washer fluid indicator is located in the Information Center area of the instrument cluster to the right of center. The washer fluid indicator consists of a stenciled cutout of the International Control and Display Symbol icon for "Windshield Washer Fluid" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber lens behind the cutout in the opaque layer of the overlay causes the icon to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by a Light Emitting Diode (LED) soldered onto the instrument cluster electronic circuit board. The washer fluid indicator is serviced as a unit with the instrument cluster. The washer fluid indicator gives an indication to the vehicle operator when the fluid level in the washer fluid reservoir is low. This indicator is controlled by a transistor on the instrument cluster electronic circuit board based upon cluster programming and a hard wired washer fluid level switch input to the cluster. The washer fluid indicator Light Emitting Diode (LED) receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or Start positions; therefore, the indicator will always be OFF when the ignition switch is in any position except ON or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the washer fluid indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the indicator is illuminated for about two seconds as a bulb test. - Washer Fluid Level Switch Input - Immediately after the bulb test, if the cluster senses ground on the washer fluid switch sense circuit for more than about thirty seconds, it turns ON the washer fluid indicator. Any time after the bulb test, the cluster must sense ground on the washer fluid switch sense circuit for more than about sixty seconds before it turns ON the indicator. Once illuminated, the indicator will remain illuminated until the ignition switch is cycled and the cluster senses an open circuit on the low washer fluid sense input. This strategy is intended to reduce the effect that fluid sloshing within the washer reservoir can have on reliable indicator operation. - Actuator Test - Each time the cluster is put through the actuator test, the indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The washer fluid level switch is connected in series between ground and the washer fluid switch sense input to the instrument cluster. For more information on the washer fluid level switch, (Refer to WASHER FLUID LEVEL SWITCH - OPERATION). For further diagnosis of the washer fluid indicator or the instrument cluster circuitry that controls the indicator, (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). The washer fluid level switch input to the cluster can be diagnosed using conventional diagnostic tools and methods. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Locations > Page 7981 Washer Fluid Level Indicator: Testing and Inspection The diagnosis found here addresses an inoperative washer fluid indicator condition. If the problem being diagnosed is related to indicator accuracy, be certain to confirm that the problem is with the indicator or washer fluid level switch input and not with a damaged or empty washer fluid reservoir, or inoperative instrument cluster indicator control circuitry. Inspect the washer fluid reservoir for proper fluid level and signs of damage or distortion that could affect washer fluid level switch performance and perform the instrument cluster actuator test before you proceed with the following diagnosis. If no washer fluid reservoir or instrument cluster control circuitry problem is found, the following procedure will help to locate a short or open in the washer fluid switch sense circuit. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Indicator Does Not Illuminate With Washer Reservoir Empty 1. Disconnect and isolate the battery negative cable. Disconnect the headlamp and dash wire harness connector for the washer fluid level switch from the washer fluid level switch connector receptacle. Check for continuity between the ground circuit cavity of the headlamp and dash wire harness connector for the washer fluid level switch and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the open ground circuit to ground (0112) as required. 2. Remove the instrument cluster from the instrument panel. Check for continuity between the washer fluid switch sense circuit cavities of the headlamp and dash wire harness connector for the washer fluid level switch and the instrument panel wire harness connector (Connector C2) for the instrument cluster. If OK, replace the faulty washer fluid level switch. If not OK, repair the open washer fluid switch sense circuit between the washer fluid level switch and the instrument cluster as required. Indicator Stays Illuminated With Washer Reservoir Full 1. Disconnect and isolate the battery negative cable. Disconnect the headlamp and dash wire harness connector for the washer fluid level switch from the washer fluid level switch connector receptacle. Check for continuity between the ground circuit terminal and the washer fluid switch sense terminal in the washer fluid level switch connector receptacle. There should be no continuity. If OK, go to Step 2. If not OK, replace the faulty washer fluid level switch. 2. Remove the instrument cluster from the instrument panel. Check for continuity between the washer fluid switch sense circuit cavity of the headlamp and dash wire harness connector for the washer fluid level switch and a good ground. There should be no continuity. If not OK, repair the shorted washer fluid switch sense circuit between the washer fluid level switch and the instrument cluster as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Washer Fluid Level Switch: Locations The washer fluid level switch is a single pole, single throw reed-type switch mounted on the outboard side of the washer reservoir forward of the two washer pump/motors, in the right front corner of the engine compartment. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7985 Washer Fluid Level Switch Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7986 Washer Fluid Level Switch: Description and Operation The washer fluid level switch is a single pole, single throw reed-type switch mounted on the outboard side of the washer reservoir forward of the two washer pump/motors, in the right front corner of the engine compartment. Only the molded plastic switch mounting flange and connector receptacle are visible when the switch is installed in the reservoir. A short nipple formation extends from the inner surface of the switch mounting flange, and a barb on the nipple near the switch mounting flange is press-fit into a rubber grommet seal installed in the mounting hole of the reservoir. A small plastic float pivots on the end of a bracket that extends from the switch nipple formation. Within the float is a small magnet, which actuates the reed switch. The washer fluid level switch cannot be adjusted or repaired. If faulty or damaged, the switch must be replaced. The washer fluid level switch uses a pivoting, oblong float to monitor the level of the washer fluid in the washer reservoir. The float contains a small magnet. When the float pivots, the changing proximity of its magnetic field will cause the contacts of the small, stationary reed switch to open or close. When the fluid level in the washer reservoir is at or above the float level, the float moves to a vertical position and the switch contacts open. When the fluid level in the washer reservoir falls below the pivoting float, the float moves to a horizontal position and the switch contacts close. The switch contacts are connected in series between ground and the washer fluid switch sense input of the instrument cluster. The switch is connected to the vehicle electrical system through a dedicated take out and connector of the headlamp and dash wire harness. The switch receives ground through another take out of the headlamp and dash wire harness with a single eyelet terminal connector that is secured under a nut to a ground stud located on the right front fender inner shield in the engine compartment. The washer fluid level switch can be diagnosed using conventional diagnostic tools and methods. (Refer to WASHER FLUID INDICATOR - DIAGNOSIS AND TESTING). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7987 Washer Fluid Level Switch: Service and Repair REMOVAL The washer fluid level switch can be removed from the washer reservoir without removing the reservoir from the vehicle. 1. Disconnect and isolate the battery negative cable. 2. Disconnect the washer hose from the barbed outlet nipple of the washer pump/motor unit and allow the washer fluid to drain into a clean container for reuse. Fig. 11 Washer Fluid Level Switch 3. Disconnect the headlamp and dash wire harness connector for the washer fluid level switch from the switch connector receptacle. NOTE: The pivoting float of the washer fluid level switch must be in a horizontal position within the reservoir in order to be removed. With the reservoir empty and in an upright position, the pivoting float will orient itself to the horizontal position when the switch connector receptacle is pointed straight downwards. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed nipple of the washer fluid level switch out of the rubber grommet seal on the outboard side of the reservoir. Care must be taken not to damage the reservoir. 5. Remove the washer fluid level switch and float from the washer reservoir. 6. Remove the rubber grommet seal from the washer fluid level switch mounting hole in the washer reservoir and discard. INSTALLATION 1. Install a new rubber grommet seal into the washer fluid level switch mounting hole in the outboard side of the washer reservoir. Always use a new rubber grommet seal on the reservoir. 2. Position the float of the washer fluid level switch through the rubber grommet seal in the washer reservoir. The connector receptacle of the washer fluid level switch should be pointed downward. 3. Press firmly and evenly on the washer fluid level switch using hand pressure until the barbed nipple is fully seated in the rubber grommet seal in the washer reservoir mounting hole. 4. Reconnect the headlamp and dash wire harness connector for the washer fluid level switch to the switch connector receptacle. 5. Reconnect the washer hose to the barbed outlet nipple of the washer pump/motor unit. 6. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Description and Operation Windshield Washer Hose: Description and Operation FRONT WASHER HOSES/TUBES The front washer plumbing consists of a small diameter rubber hose that is routed from the barbed outlet nipple of the front washer pump/motor on the washer reservoir through the engine compartment along the headlamp and dash wire harness near the right inner fender shield to the dash panel. The front washer hose passes from the engine compartment into the cowl plenum area through a dedicated hole with a rubber grommet near the right end of the cowl plenum panel. Beneath the cowl plenum cover/grille panel, a molded plastic in-line fitting with barbed nipples joins the engine compartment hose to a cowl plenum cover/grille panel hose. The cowl plenum cover/grille panel hose is routed through locating clips molded to the underside of the cowl plenum cover/grille panel to a molded plastic eye fitting with barbed nipples and an integral check valve near the passenger side washer nozzle. Two hoses are then routed from the eye fitting through additional locating clips on the underside of the cowl plenum cover/grille panel to the two washer nozzles. Washer hose is available for service only as roll stock, which must then be cut to length. The molded plastic washer hose fittings cannot be repaired. If these fittings are faulty or damaged, they must be replaced. Washer fluid in the washer reservoir is pressurized and fed by the front washer pump/motor through the front washer system plumbing and fittings to the two front washer nozzles. Whenever routing the washer hose or a wire harness containing a washer hose, it must be routed away from hot, sharp, or moving parts; and, sharp bends that might pinch the hose must be avoided. REAR WASHER HOSES/TUBES The rear washer plumbing consists of small diameter rubber hose, the molded plastic rear washer system check valve, and numerous routing clips. The rear washer system engine compartment hose is connected to the barbed outlet nipple of the rear washer pump/motor unit on the washer reservoir and routed through the engine compartment along the headlamp and dash wire harness near the right inner fender shield to the back of the right front wheel house. At the back of the right front wheel house, the engine compartment hose is joined to the passenger compartment hose by the molded plastic rear washer system check valve. The passenger compartment hose passes through a hole with a rubber grommet in the dash panel into the passenger compartment. The passenger compartment hose is then routed below the instrument panel, down the right cowl side inner panel, and along the right side of the floor panel near the body wire harness to the right rear wheel house. At the rear wheel house, the passenger compartment hose is routed up to the right quarter inner panel and below the quarter glass opening to the D-pillar at the rear of the vehicle. At the rear of the vehicle, the passenger compartment hose is routed up the D-pillar and along the upper liftgate opening inner panel toward the left side of the vehicle. Near the center of the liftgate opening the hose passes through a clearance hole in the liftgate opening inner panel and through a rubber grommet in a hole in the upper liftgate opening outer panel to the outside of the vehicle. From the outside of the vehicle, the hose passes through another hole with a rubber grommet into the upper inner liftgate panel to the rear washer nozzle. Washer hose is available for service only as roll stock, which must then be cut to length. The molded plastic washer hose fittings and routing clips cannot be repaired. If these fittings or clips are faulty or damaged, they must be replaced. Washer fluid in the washer reservoir is pressurized and fed by the rear washer pump/motor through the rear washer system plumbing and fittings to the rear washer nozzle on the liftgate outer panel above the liftgate glass. Whenever routing the washer hose or a wire harness containing a washer hose, it must be routed away from hot, sharp, or moving parts; and, sharp bends that might pinch the hose must be avoided. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations Windshield Washer Motor: Locations Fig. 2 Front Washer Pump/Motor The front washer pump/motor unit is located on the outboard side of the washer reservoir, near the bottom in the right front corner of the engine compartment. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations > Page 7994 Fig. 5 Rear Washer Pump/Motor The rear washer pump/motor unit is located on the outboard side of the washer reservoir, near the bottom in the right front corner of the engine compartment. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations > Page 7995 Windshield Washer Motor: Diagrams Front Washer Pump/Motor Rear Washer Pump/Motor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations > Page 7996 Windshield Washer Motor: Description and Operation Fig. 2 Front Washer Pump/Motor FRONT WASHER PUMP/MOTOR The front washer pump/motor unit is located on the outboard side of the washer reservoir, near the bottom in the right front corner of the engine compartment. A small permanently lubricated and sealed electric motor is coupled to the rotor-type washer pump. A seal flange with a large barbed inlet nipple on the pump housing passes through a rubber grommet seal installed in the dedicated mounting hole near the bottom of the washer reservoir. A smaller barbed outlet nipple on the pump housing connects the unit to the front washer hose. The front washer pump/motor unit is retained on the reservoir by the interference fit between the barbed pump inlet nipple and the grommet seal, which is a light press fit. An integral electrical connector receptacle is located on the motor housing. The front washer pump/motor unit cannot be repaired. If faulty or damaged, the entire washer pump/motor unit must be replaced. The front washer pump/motor unit is connected to the vehicle electrical system through a single take out and two-cavity connector of the headlamp and dash wire harness. The front washer pump/motor is grounded at all times through a take out of the headlamp and dash wire harness with a single eyelet terminal connector that is secured by a nut to a ground stud located on the right front fender inner shield in the engine compartment. The front washer pump/motor receives battery current on a front washer pump/motor control circuit through an output of the Central Timer Module (CTM) whenever the CTM receives an input through the closed contacts of the momentary front washer switch within the multi- function switch. Washer fluid is gravity-fed from the washer reservoir to the inlet side of the washer pump. When the pump motor is energized, the rotor- type pump pressurizes the washer fluid and forces it through the pump outlet nipple, the front washer plumbing, and the front washer nozzles onto the windshield glass. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations > Page 7997 Fig. 5 Rear Washer Pump/Motor REAR WASHER PUMP/MOTOR The rear washer pump/motor unit is located on the outboard side of the washer reservoir, near the bottom in the right front corner of the engine compartment. A small permanently lubricated and sealed electric motor is coupled to the rotor-type washer pump. A seal flange with a large barbed inlet nipple on the pump housing passes through a rubber grommet seal installed in one of two dedicated mounting holes near the bottom of the washer reservoir. The rear washer pump/motor unit is always mounted in the upper pump mounting hole of the reservoir. A smaller barbed outlet nipple on the pump housing connects the unit to the rear washer hose. The rear washer pump/motor unit is retained on the reservoir by the interference fit between the barbed pump inlet nipple and the grommet seal, which is a light press fit. An integral electrical connector receptacle is located on the motor housing. The rear washer pump/motor unit cannot be repaired. If faulty or damaged, the entire washer pump/motor unit must be replaced. The rear washer pump/motor unit is connected to the vehicle electrical system through a single take out and two-cavity connector of the headlamp and dash wire harness. The rear washer pump/motor is grounded at all times through a take out of the headlamp and dash wire harness with a single eyelet terminal connector that is secured by a nut to a ground stud located on the right front fender inner shield in the engine compartment. The rear washer pump/motor receives battery current on a rear washer pump/ motor control circuit through an output of the air conditioner-heater control whenever the momentary contacts of the rear washer switch within the air conditioner-heater control are closed. Washer fluid is gravity-fed from the washer reservoir to the inlet side of the washer pump. When the pump motor is energized, the rotor-type pump pressurizes the washer fluid and forces it through the pump outlet nipple, the rear washer plumbing, and the rear washer nozzle onto the liftgate glass. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Service and Repair > Front Washer Pump/Motor Replacement Windshield Washer Motor: Service and Repair Front Washer Pump/Motor Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. Fig. 3 Front Washer Pump/Motor Remove/Install 2. Disconnect the headlamp and dash wire harness connector for the front washer pump/motor from the motor connector receptacle. 3. Disconnect the washer supply hose from the barbed outlet nipple of the front washer pump/motor and allow the washer fluid to drain into a clean container for reuse. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed inlet nipple of the washer pump out of the rubber grommet seal in the reservoir. Care must be taken not to damage the reservoir. 5. Remove the rubber grommet seal from the washer pump mounting hole in the washer reservoir and discard. INSTALLATION 1. Install a new rubber grommet seal into the washer pump mounting hole in the washer reservoir. Always use a new rubber grommet seal on the reservoir. 2. Position the barbed inlet nipple of the washer pump to the rubber grommet seal in the reservoir. 3. Using hand pressure, press firmly and evenly on the washer pump until the barbed inlet nipple is fully seated in the rubber grommet seal in the washer reservoir mounting hole. 4. Reconnect the front washer hose to the barbed outlet nipple of the front washer pump. 5. Reconnect the headlamp and dash wire harness connector for the front washer pump/motor to the motor connector receptacle. 6. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Service and Repair > Front Washer Pump/Motor Replacement > Page 8000 Windshield Washer Motor: Service and Repair Rear Washer Pump/Motor Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. Fig. 6 Rear Washer Pump/Motor Remove/Install 2. Disconnect the headlamp and dash wire harness connector for the rear washer pump/motor from the motor connector receptacle. 3. Disconnect the washer supply hose from the barbed outlet nipple of the rear washer pump/motor and allow the washer fluid to drain into a clean container for reuse. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed inlet nipple of the washer pump out of the rubber grommet seal in the reservoir. Care must be taken not to damage the reservoir. 5. Remove the rubber grommet seal from the washer pump mounting hole in the washer reservoir and discard. INSTALLATION 1. Install a new rubber grommet seal into the washer pump mounting hole in the washer reservoir. Always use a new rubber grommet seal on the reservoir. 2. Position the barbed inlet nipple of the washer pump to the rubber grommet seal in the reservoir. 3. Using hand pressure, press firmly and evenly on the washer pump until the barbed inlet nipple is fully seated in the rubber grommet seal in the washer reservoir mounting hole. 4. Reconnect the rear washer hose to the barbed outlet nipple of the rear washer pump. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Service and Repair > Front Washer Pump/Motor Replacement > Page 8001 Fig.3 Rear Check Valve 5. Reconnect the headlamp and dash wire harness connector for the rear washer pump/motor to the motor connector receptacle. 6. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations Windshield Washer Pump: Locations Fig. 2 Front Washer Pump/Motor The front washer pump/motor unit is located on the outboard side of the washer reservoir, near the bottom in the right front corner of the engine compartment. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 8005 Fig. 5 Rear Washer Pump/Motor The rear washer pump/motor unit is located on the outboard side of the washer reservoir, near the bottom in the right front corner of the engine compartment. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 8006 Windshield Washer Pump: Diagrams Front Washer Pump/Motor Rear Washer Pump/Motor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 8007 Windshield Washer Pump: Description and Operation Fig. 2 Front Washer Pump/Motor FRONT WASHER PUMP/MOTOR The front washer pump/motor unit is located on the outboard side of the washer reservoir, near the bottom in the right front corner of the engine compartment. A small permanently lubricated and sealed electric motor is coupled to the rotor-type washer pump. A seal flange with a large barbed inlet nipple on the pump housing passes through a rubber grommet seal installed in the dedicated mounting hole near the bottom of the washer reservoir. A smaller barbed outlet nipple on the pump housing connects the unit to the front washer hose. The front washer pump/motor unit is retained on the reservoir by the interference fit between the barbed pump inlet nipple and the grommet seal, which is a light press fit. An integral electrical connector receptacle is located on the motor housing. The front washer pump/motor unit cannot be repaired. If faulty or damaged, the entire washer pump/motor unit must be replaced. The front washer pump/motor unit is connected to the vehicle electrical system through a single take out and two-cavity connector of the headlamp and dash wire harness. The front washer pump/motor is grounded at all times through a take out of the headlamp and dash wire harness with a single eyelet terminal connector that is secured by a nut to a ground stud located on the right front fender inner shield in the engine compartment. The front washer pump/motor receives battery current on a front washer pump/motor control circuit through an output of the Central Timer Module (CTM) whenever the CTM receives an input through the closed contacts of the momentary front washer switch within the multi- function switch. Washer fluid is gravity-fed from the washer reservoir to the inlet side of the washer pump. When the pump motor is energized, the rotor- type pump pressurizes the washer fluid and forces it through the pump outlet nipple, the front washer plumbing, and the front washer nozzles onto the windshield glass. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 8008 Fig. 5 Rear Washer Pump/Motor REAR WASHER PUMP/MOTOR The rear washer pump/motor unit is located on the outboard side of the washer reservoir, near the bottom in the right front corner of the engine compartment. A small permanently lubricated and sealed electric motor is coupled to the rotor-type washer pump. A seal flange with a large barbed inlet nipple on the pump housing passes through a rubber grommet seal installed in one of two dedicated mounting holes near the bottom of the washer reservoir. The rear washer pump/motor unit is always mounted in the upper pump mounting hole of the reservoir. A smaller barbed outlet nipple on the pump housing connects the unit to the rear washer hose. The rear washer pump/motor unit is retained on the reservoir by the interference fit between the barbed pump inlet nipple and the grommet seal, which is a light press fit. An integral electrical connector receptacle is located on the motor housing. The rear washer pump/motor unit cannot be repaired. If faulty or damaged, the entire washer pump/motor unit must be replaced. The rear washer pump/motor unit is connected to the vehicle electrical system through a single take out and two-cavity connector of the headlamp and dash wire harness. The rear washer pump/motor is grounded at all times through a take out of the headlamp and dash wire harness with a single eyelet terminal connector that is secured by a nut to a ground stud located on the right front fender inner shield in the engine compartment. The rear washer pump/motor receives battery current on a rear washer pump/ motor control circuit through an output of the air conditioner-heater control whenever the momentary contacts of the rear washer switch within the air conditioner-heater control are closed. Washer fluid is gravity-fed from the washer reservoir to the inlet side of the washer pump. When the pump motor is energized, the rotor-type pump pressurizes the washer fluid and forces it through the pump outlet nipple, the rear washer plumbing, and the rear washer nozzle onto the liftgate glass. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Front Washer Pump/Motor Replacement Windshield Washer Pump: Service and Repair Front Washer Pump/Motor Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. Fig. 3 Front Washer Pump/Motor Remove/Install 2. Disconnect the headlamp and dash wire harness connector for the front washer pump/motor from the motor connector receptacle. 3. Disconnect the washer supply hose from the barbed outlet nipple of the front washer pump/motor and allow the washer fluid to drain into a clean container for reuse. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed inlet nipple of the washer pump out of the rubber grommet seal in the reservoir. Care must be taken not to damage the reservoir. 5. Remove the rubber grommet seal from the washer pump mounting hole in the washer reservoir and discard. INSTALLATION 1. Install a new rubber grommet seal into the washer pump mounting hole in the washer reservoir. Always use a new rubber grommet seal on the reservoir. 2. Position the barbed inlet nipple of the washer pump to the rubber grommet seal in the reservoir. 3. Using hand pressure, press firmly and evenly on the washer pump until the barbed inlet nipple is fully seated in the rubber grommet seal in the washer reservoir mounting hole. 4. Reconnect the front washer hose to the barbed outlet nipple of the front washer pump. 5. Reconnect the headlamp and dash wire harness connector for the front washer pump/motor to the motor connector receptacle. 6. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Front Washer Pump/Motor Replacement > Page 8011 Windshield Washer Pump: Service and Repair Rear Washer Pump/Motor Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. Fig. 6 Rear Washer Pump/Motor Remove/Install 2. Disconnect the headlamp and dash wire harness connector for the rear washer pump/motor from the motor connector receptacle. 3. Disconnect the washer supply hose from the barbed outlet nipple of the rear washer pump/motor and allow the washer fluid to drain into a clean container for reuse. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed inlet nipple of the washer pump out of the rubber grommet seal in the reservoir. Care must be taken not to damage the reservoir. 5. Remove the rubber grommet seal from the washer pump mounting hole in the washer reservoir and discard. INSTALLATION 1. Install a new rubber grommet seal into the washer pump mounting hole in the washer reservoir. Always use a new rubber grommet seal on the reservoir. 2. Position the barbed inlet nipple of the washer pump to the rubber grommet seal in the reservoir. 3. Using hand pressure, press firmly and evenly on the washer pump until the barbed inlet nipple is fully seated in the rubber grommet seal in the washer reservoir mounting hole. 4. Reconnect the rear washer hose to the barbed outlet nipple of the rear washer pump. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Front Washer Pump/Motor Replacement > Page 8012 Fig.3 Rear Check Valve 5. Reconnect the headlamp and dash wire harness connector for the rear washer pump/motor to the motor connector receptacle. 6. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Locations Windshield Washer Reservoir: Locations Fig. 12 Washer Reservoir The molded plastic washer fluid reservoir is integral to, and located on the right end of the upper radiator shroud in the right front corner of the engine compartment. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Locations > Page 8016 Windshield Washer Reservoir: Description and Operation Fig. 12 Washer Reservoir A single washer fluid reservoir is used for both the front and rear washer systems. The molded plastic washer fluid reservoir is integral to, and located on the right end of the upper radiator shroud in the right front corner of the engine compartment. A bright yellow plastic filler cap with a rubber seal and an International Control and Display Symbol icon for "Windshield Washer" and the text "Washer Fluid Only" molded into it snaps over the open end of the filler neck. The cap hinges on and is secured to a molded-in hook formation on the top of the reservoir just inboard of the filler neck when it is removed for inspecting or adjusting the fluid level in the reservoir. There are separate, dedicated holes on the outboard side of the reservoir provided for the mounting of the front and rear washer/pump motor units and the washer fluid level switch. The washer reservoir is serviced only as a unit with the upper radiator shroud. The washer reservoir cannot be repaired and, if faulty or damaged, the upper fan shroud unit must be replaced. The grommet seals for the washer pump/motor units and the washer fluid level switch, and the filler cap are each available for service replacement. The washer fluid reservoir provides a secure, on-vehicle storage location for a large reserve of washer fluid for operation of the front and rear washer systems. The washer reservoir filler neck provides a clearly marked and readily accessible point from which to add washer fluid to the reservoir. The front and rear washer/pump motor units are located in a sump area near the bottom of the reservoir to be certain that washer fluid will be available to the pump as the fluid level in the reservoir becomes depleted. The front washer pump/motor unit is mounted in the lowest position in the sump so that the front washers will operate even after the rear washer system will no longer operate. The washer fluid level switch is mounted just above the sump area of the reservoir so that there will be adequate warning to the vehicle operator that the washer fluid level is low, before the washer system will no longer operate. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Locations > Page 8017 Windshield Washer Reservoir: Service and Repair REMOVAL Fig. 13 Upper Fan Shroud Remove/Install NOTE: The washer reservoir is integral to the right end of the upper radiator shroud, and the engine coolant reserve/overflow tank is integral to the left end of the upper radiator shroud . 1. Disconnect and isolate the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Locations > Page 8018 Fig. 14 Washer Reservoir Remove/Install 2. Disconnect the headlamp and dash wire harness connector for the washer fluid level switch from the switch connector receptacle 3. Disconnect the headlamp and dash wire harness connectors for the front and rear washer pump/motor units from the motor connector receptacles. 4. Disconnect the washer hoses from the barbed outlet nipples of the front and rear washer pump/motors and allow the washer fluid to drain into a clean container for reuse. 5. Disconnect the engine coolant reserve/overflow hose from the nipple of the radiator filler spout in the upper radiator hose. 6. Remove the six screws that secure the upper radiator shroud to the radiator. 7. Disengage the locator dowels on the bottom of the upper radiator shroud from the locator holes in the upper flanges of the lower shroud. 8. Remove the upper radiator shroud from the radiator. INSTALLATION 1. Install the fan shroud into vehicle. NOTE: The washer reservoir is integral to the right end of the upper radiator shroud, and the engine coolant reserve/overflow tank is integral to the left end of the upper radiator shroud. 2. Position the upper radiator shroud onto the radiator. 3. Engage the locator dowels on the bottom of the upper radiator shroud into the locator holes in the upper flanges of the lower shroud. 4. Install and tighten the six screws that secure the upper radiator shroud to the radiator. Tighten the screws to 6 Nm (50 in. lbs.). 5. Reconnect the engine coolant reserve/overflow hose to the nipple of the radiator filler spout in the upper radiator hose. 6. Reconnect the washer hoses to the barbed outlet nipples of the front and rear washer pump/motors. 7. Reconnect the headlamp and dash wire harness connectors for the front and rear washer pump/motor units to the motor connector receptacles. 8. Reconnect the headlamp and dash wire harness connector for the washer fluid level switch to the switch connector receptacle. 9. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 10. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Locations Windshield Washer Spray Nozzle: Locations The two front washer nozzles have integral snap features that secure them in dedicated holes in the cowl plenum cover/grille panel located near the base of the windshield. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Locations > Page 8022 Windshield Washer Spray Nozzle: Description and Operation FRONT WASHER NOZZLE The two front washer nozzles have integral snap features that secure them in dedicated holes in the cowl plenum cover/grille panel located near the base of the windshield. The domed upper surface of the washer nozzle is visible on the top of the plenum cover/grille panel, and the nozzle orifice is oriented towards the windshield glass. The washer plumbing fittings for the front washer nozzles are concealed beneath the cowl plenum cover/grille panel. These fluidic washer nozzles are constructed of molded plastic. The cowl plenum cover/grille panel must be removed from the vehicle to access the nozzles for service. The front washer nozzles cannot be adjusted or repaired and, if faulty or damaged, they must be replaced. The two front washer nozzles are designed to dispense washer fluid into the wiper pattern area on the outside of the windshield glass. Pressurized washer fluid is fed to each nozzle from the washer reservoir by the front washer pump/motor through rubber hoses, which are attached to a barbed nipple on each washer nozzle below the cowl plenum cover/grille panel. The front washer nozzles incorporate a fluidic design, which causes the nozzle to emit the pressurized washer fluid as an oscillating stream to more effectively cover a larger area of the glass area to be cleaned. REAR WASHER NOZZLE The rear washer nozzle is a fluidic type unit constructed of molded plastic and has a rubber seal and integral snap features on the back of it. The nozzle is secured by a snap fit in a dedicated mounting hole in the liftgate outer panel above the liftgate glass. The rear washer nozzle unit cannot be adjusted or repaired. If faulty or damaged, the entire nozzle unit must be replaced. The rear washer nozzle is designed to dispense washer fluid into the wiper pattern area on the outside of the liftgate glass. Pressurized washer fluid is fed to the nozzle from the washer reservoir by the rear washer pump/motor through a single hose, which is attached to a barbed nipple on the back of the rear washer nozzle. The rear washer nozzle incorporates a fluidic design, which causes the nozzle to emit the pressurized washer fluid as an oscillating stream to more effectively cover a larger area of the glass area to be cleaned. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Service and Repair > Front Windshield Washer Spray Nozzle: Service and Repair Front REMOVAL 1. Remove the front wiper arms from the wiper pivots. (Refer to FRONT WIPER ARMS REMOVAL). 2. Remove the cowl plenum cover/grille panel from the top of the cowl plenum. 3. From the underside of the cowl plenum cover/grille panel, disconnect the washer hose from the front washer nozzle fitting. 4. From the underside of the cowl plenum cover/grille panel, compress the snap features of the front washer nozzle and push the nozzle out through the top of the panel. INSTALLATION 1. Align the front washer nozzle with the opening on the top of cowl plenum cover/grille panel. 2. Using hand pressure, push the front washer nozzle into the opening from the top of the cowl plenum cover/grille panel until the snap features of the nozzle are fully engaged. 3. From the underside of the cowl plenum cover/ grille panel, reconnect the washer hose to the front washer nozzle fitting. 4. Reinstall the cowl plenum cover/grille panel onto the top of the cowl plenum. 5. Reinstall the front wiper arms onto the wiper pivots. (Refer to FRONT WIPER ARMS INSTALLATION). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Service and Repair > Front > Page 8025 Windshield Washer Spray Nozzle: Service and Repair Rear REMOVAL 1. Using a trim stick or another suitable wide flat-bladed tool, gently pry at the sides of the rear washer nozzle to release the snap features that secure it in the mounting hole of the liftgate outer panel. Fig. 4 Rear Washer Nozzle Remove/Install 2. Pull the rear washer nozzle out from the liftgate outer panel far enough to access the washer supply hose. 3. Disconnect the washer supply hose from the barbed nipple of the rear washer nozzle. 4. Remove the rear washer nozzle from the liftgate. INSTALLATION 1. Position the rear washer nozzle to the mounting hole in the liftgate outer panel. 2. Reconnect the washer supply hose to the barbed nipple on the back of the rear washer nozzle. 3. Insert the rear washer nozzle supply hose and nipple through the mounting hole into the liftgate. 4. Using hand pressure, push firmly and evenly on the rear washer nozzle until the snap features lock into place on the inside of the mounting hole in the liftgate outer panel. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Locations Wiper Arm: Locations The front wiper arms are the rigid members located between the wiper pivots that protrude from the cowl plenum cover/grille panel near the base of the windshield and the wiper blades on the windshield glass. Fig. 7 Rear Wiper Arm The rear wiper arm is the rigid member located between the rear wiper motor output shaft that protrudes from the outer liftgate panel near the base of the liftgate glass opening and the rear wiper blade. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Locations > Page 8029 Wiper Arm: Description and Operation FRONT WIPER ARM The front wiper arms are the rigid members located between the wiper pivots that protrude from the cowl plenum cover/grille panel near the base of the windshield and the wiper blades on the windshield glass. These wiper arms feature an over-center hinge that allows easy access to the windshield glass for cleaning. The wiper arm has a die cast metal pivot end with a large mounting hole with internal serrations at one end. A molded black plastic cap fits over the wiper arm retaining nut to conceal the nut and this mounting hole following wiper arm installation. The wide end of a tapered, stamped steel channel hinges on and is secured with a hinge pin to the blade end of the wiper arm pivot end. One end of a long, rigid, stamped steel strap, with a small hole near its pivot end, is riveted and crimped within the narrow end of the stamped steel channel. The tip of the wiper blade end of this strap is bent back under itself to form a small hook. Concealed within the stamped steel channel, one end of a long spring is engaged with a wire hook on the underside of the die cast pivot end, while the other end of the spring is hooked through the small hole in the steel strap. The entire wiper arm has a satin black finish applied to all of its visible surfaces. A wiper arm cannot be adjusted or repaired. If damaged or faulty, the entire wiper arm unit must be replaced. The front wiper arms are designed to mechanically transmit the motion from the wiper pivots to the wiper blades. The wiper arm must be properly indexed to the wiper pivot in order to maintain the proper wiper blade travel on the glass. The mounting hole formation with internal serrations in the wiper arm pivot end interlocks with the serrations on the outer circumference of the wiper pivot driver, allowing positive engagement and finite adjustment of this connection. The mounting nut locks the wiper arm to the threaded stud on the wiper pivot. The spring-loaded wiper arm hinge controls the down-force applied through the tip of the wiper arm to the wiper blade on the glass. The hook formation on the tip of the wiper arm provides a cradle for securing and latching the wiper blade pivot block to the wiper arm. Fig. 7 Rear Wiper Arm REAR WIPER ARM The rear wiper arm is the rigid member located between the rear wiper motor output shaft that protrudes from the outer liftgate panel near the base of the liftgate glass opening and the rear wiper blade. The wiper arm has a die cast metal pivot end. This pivot end has a mounting hole in it with internal serrations. A molded black plastic cap fits over the wiper arm retaining nut to conceal the nut and this mounting hole following wiper arm installation. The wide end of a tapered, stamped steel channel is secured with a hinge pin to the pivot end of the wiper arm. One end of a long, rigid, stamped steel strap, with a small hole near its pivot end, is riveted and crimped within the narrow end of the stamped steel channel. The tip of the wiper blade end of this strap is bent back under itself to form a small hook. Concealed within the stamped steel channel, one end of a long spring is engaged to the hinge pin on the underside of the die cast pivot end, while the other end of the spring is hooked through the small hole in the steel strap. The entire wiper arm has a satin black finish applied to all of its visible surfaces. A wiper arm cannot be adjusted or repaired. If damaged or faulty, the entire wiper arm unit must be replaced. The rear wiper arm is designed to mechanically transmit the motion from the rear wiper motor output shaft to the rear wiper blade. The wiper arm must be properly indexed to the motor output shaft in order to maintain the proper wiper blade travel on the glass. The hole with internal serrations in the wiper arm pivot end interlocks with the serrations on the outer circumference of the motor output shaft, allowing positive engagement and finite adjustment of this connection. A hex nut secures the wiper arm pivot end to the threads on the motor output shaft and the plastic nut cap snaps over this connection for a neat appearance. The spring-loaded wiper arm hinge controls the down-force applied through the tip of the wiper arm to the wiper blade on the glass. The hook formation on the tip of the wiper arm provides a cradle for securing and latching the wiper blade pivot block to the wiper arm. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Front Wiper Arms Replacement Wiper Arm: Service and Repair Front Wiper Arms Replacement REMOVAL 1. Lift the front wiper arm to its over-center position to hold the wiper blade off of the glass and relieve the spring tension on the wiper arm to wiper pivot connection. 2. Open the hood of the vehicle. Fig. 4 Wiper Arm Remove/Install 3. Carefully pry the plastic nut cap off of the nut on the pivot end of the front wiper arm. 4. Remove the nut that secures the front wiper arm to the wiper pivot shaft. Wiper Arm Puller 5. Use a suitable battery terminal puller to disengage the front wiper arm from the wiper pivot shaft splines. 6. Remove the wiper arm pivot end from the wiper pivot. INSTALLATION NOTE: Be certain that the wiper motor is in the park position before attempting to install the front wiper arms. Turn the ignition switch to the ON position and move the multi-function switch control knob to its OFF position. If the wiper pivots move, wait until they stop moving, then turn the ignition switch back to the OFF position. The front wiper motor is now in its park position. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Front Wiper Arms Replacement > Page 8032 Wiper Arm Installation 1. The front wiper arms must be indexed to the wiper pivots with the front wiper motor in the park position to be properly installed. Position the wiper arm pivot ends onto the wiper pivots so that the lower edge of the blade is aligned with the wiper alignment lines concealed in the upper margin of the lower windshield blackout area, ± 15 mm (+/- 0.59 in.). 2. Once the wiper blade is aligned, lift the front wiper arm away from the windshield slightly to relieve the spring tension on the pivot end and push the pivot hole on the end of the wiper arm down over the wiper pivot shaft. 3. Install and tighten the nut that secures the front wiper arm to the wiper pivot shaft. Tighten the nut to 23.7 Nm (210 in. lbs.). 4. Wet the windshield glass, then operate the front wipers. Turn the wiper switch to the OFF position, then check for the correct wiper arm position and readjust as required. 5. Reinstall the plastic nut cap onto the front wiper arm pivot nut. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Front Wiper Arms Replacement > Page 8033 Wiper Arm: Service and Repair Rear Wiper Arm Replacement REMOVAL Fig. 8 Rear Wiper Arm Remove/Install 1. Carefully pry the plastic nut cap OFF of the nut on the pivot end of the wiper arm. 2. Remove the nut that secures the rear wiper arm to the rear wiper motor output shaft. Wiper Arm Puller 3. Use a suitable battery terminal puller to disengage the front wiper arm from the rear wiper motor output shaft splines. 4. Using a slight rocking action, remove the rear wiper arm pivot end from the rear wiper motor output shaft. INSTALLATION NOTE: Be certain that the rear wiper motor is in the park position before attempting to install the wiper arm. Turn the ignition switch to the ON position and move the rear wiper switch to its OFF position. If the wiper motor output shaft moves, wait until it stops moving, then turn the ignition switch back to the OFF position. The wiper motor is now in its park position. 1. The rear wiper arm must be indexed to the motor output shaft with the rear wiper motor in the park position to be properly installed. Position the rear wiper arm pivot end onto the motor output shaft so that the center of the wiper blade is located between the upper margin of the lower liftgate glass blackout area and the lower edge of the trademark on the lower right corner of the liftgate glass. 2. Install and tighten the wiper arm retaining nut. Tighten the nut to 18 Nm (160 in. lbs.). 3. Gently lower the wiper arm until the wiper blade rests on the glass. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Front Wiper Arms Replacement > Page 8034 4. Wet the liftgate glass, then operate the rear wiper. Turn the rear wiper switch to the OFF position, then check for the correct wiper arm position and adjust as required. 5. Reinstall the plastic nut cap onto the nut on the pivot end of the rear wiper arm. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) 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 Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Page 8048 Wiper Blade: Description and Operation FRONT WIPER BLADE Each wiper blade is secured by an integral latching pivot block to the hook formation on the tip of the wiper arms, and rests on the glass near the base of the windshield when the wipers are not in operation. The wiper blade consists of the following components: Superstructure - The superstructure includes several stamped steel bridges and links with claw formations that grip the wiper blade element. The driver side and passenger side wiper blades are not interchangeable. The superstructure of the driver side blade features an additional bridge, which provides an additional set of claws to retain the wiper squeegees. Their are eight sets of claws on the driver side, and six sets of claws used on the passenger side. Also included in this unit is the latching, molded plastic pivot block that secures the super- structure to the wiper arm. All of the metal components of the wiper blade have a satin black finish applied. - Element - The wiper element or squeegee is the resilient rubber member of the wiper blade that contacts the glass. - Flexor - The flexor is a rigid metal component running along the length of each side of the wiper element where it is gripped by the claws of the superstructure. All Durango models have two 50 centimeter (19.69 inch) wiper blades with non-replaceable rubber elements (squeegees). These wiper blades also include an anti-lift feature. The wiper blades cannot be adjusted or repaired. If faulty, worn, or damaged the entire wiper blade unit must be replaced. The wiper blades are moved back and forth across the glass by the wiper arms when the wipers are being operated. The wiper blade superstructure is the flexible frame that grips the wiper blade element and evenly distributes the force of the spring-loaded wiper arm along the length of the element. The combination of the wiper arm force and the flexibility of the superstructure makes the element conform to and maintain proper contact with the glass, even as the blade is moved over the varied curvature found across the glass surface. The wiper element flexor provides the claws of the blade superstructure with a rigid, yet flexible component on the element which can be gripped. The rubber element is designed to be stiff enough to maintain an even cleaning edge as it is drawn across the glass, but resilient enough to conform to the glass surface and flip from one cleaning edge to the other each time the wiper blade changes directions. Fig. 10 Rear Wiper Blade REAR WIPER BLADE The rear wiper blade is secured by an integral latching pivot block to the hook formation on the tip of the rear wiper arm, and rests on the glass near the base of the liftgate glass when the wiper is not in operation. The rear wiper blade consists of the following components: Superstructure - The superstructure includes a stamped steel bridge and plastic links with claw formations that grip the wiper blade element. Also included in this unit is the latching, molded plastic pivot block that secures the superstructure to the wiper arm. All of the metal components of the wiper blade have a satin black finish applied. - Element - The wiper element or squeegee is the resilient rubber member of the wiper blade that contacts the glass. - Flexor - The flexor is a rigid metal component running along the length of each side of the wiper element where it is gripped by the claws of the superstructure. All Durango models with the rear wiper and washer system have one 40.0-centimeter (15.75-inch) rear wiper blade with a non-replaceable element (squeegee). The wiper blade cannot be adjusted or repaired. If faulty, worn, or damaged the entire wiper blade unit must be replaced. The rear wiper blade is moved back and forth across the glass by the wiper arm when the rear wiper system is in operation. The wiper blade Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Page 8049 superstructure is the flexible frame that grips the wiper blade element and evenly distributes the force of the spring-loaded wiper arm along the length of the element. The combination of the wiper arm force and the flexibility of the superstructure makes the element conform to and maintain proper contact with the liftgate glass, even as the blade is moved over the varied curvature found across the glass surface. The wiper element flexor provides the claws of the blade superstructure with a rigid, yet flexible component on the element which can be gripped. The rubber element is designed to be stiff enough to maintain an even cleaning edge as it is drawn across the glass, but resilient enough to conform to the glass surface and flip from one cleaning edge to the other each time the wiper blade changes directions. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Front Wiper Blade Replacement Wiper Blade: Service and Repair Front Wiper Blade Replacement REMOVAL NOTE: The driver side and passenger side front wiper blades are not interchangeable. The driver side wiper blade has an extra bridge and eight pairs of claws securing the wiper element. The passenger side wiper blade has six pairs of claws securing the wiper element. The notched retainer end of both wiper elements should always be oriented towards the end of the wiper blade that is nearest to the wiper pivot. 1. Turn the wiper control knob on the end of the multi-function switch control stalk to the ON position. Cycle the front wiper blades to a convenient working location on the windshield by turning the ignition switch to the ON and OFF positions. 2. Lift the front wiper arm to raise the wiper blade and element off of the glass. Wiper Blade Remove/Install - Typical 3. To remove the front wiper blade from the wiper arm, push the pivot block latch release tab under the tip of the arm and slide the blade away from the tip towards the pivot end of the arm far enough to disengage the pivot block from the hook. 4. Extract the hook formation on the tip of the front wiper arm from the opening in the wiper blade superstructure ahead of the wiper blade pivot block/ latch unit. CAUTION: Do not allow the front wiper arm to spring back against the glass without the wiper blade in place or the glass may be damaged. 5. Gently lower the front wiper arm tip onto the glass. INSTALLATION NOTE: The driver side and passenger side front wiper blades are not interchangeable. The driver side wiper blade has an extra bridge and eight pairs of claws securing the wiper element. The passenger side wiper blade has six pairs of claws securing the wiper element. The notched retainer end of both wiper elements should always be oriented towards the end of the wiper blade that is nearest to the wiper pivot. 1. Lift the front wiper arm off of the windshield glass. 2. Position the front wiper blade near the hook formation on the tip of the arm with the notched retainer for the wiper element oriented towards the end of the wiper arm that is nearest to the wiper pivot. 3. Insert the hook formation on the tip of the front wiper arm through the opening in the wiper blade superstructure ahead of the wiper blade pivot block/latch unit far enough to engage the pivot block with the hook. 4. Slide the front wiper blade pivot block/latch up into the hook formation on the tip of the wiper arm until the latch release tab snaps into its locked position. 5. Gently lower the front wiper blade onto the glass. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Front Wiper Blade Replacement > Page 8052 Wiper Blade: Service and Repair Rear Wiper Blade Replacement REMOVAL NOTE: The notched retainer end of the wiper element should always be oriented towards the end of the wiper blade that is nearest to the rear wiper motor output shaft. Fig. 11 Rear Wiper Blade Remove/Install 1. Lift up the retainer release tab on the top of the wiper arm to unlatch it from the wiper arm. 2. Raise the retainer release tab until it is perpendicular to the rear wiper blade. 3. Lift the rear wiper arm to raise the wiper blade off of the liftgate glass. 4. Slide the rear wiper blade away from the hook formation on the tip of the wiper arm and towards the pivot end of the arm far enough to disengage the pivot block from the hook. 5. Extract the hook formation on the tip of the wiper arm from the opening in the wiper blade superstructure ahead of the wiper blade pivot pin' latch unit. CAUTION: Do not allow the wiper arm to spring back against the glass without the wiper blade in place or the glass may be damaged. 6. Gently lower the wiper arm tip onto the glass. INSTALLATION NOTE: The notched retainer end of the wiper element should always be oriented towards the end of the wiper blade that is nearest to the wiper motor output shaft. 1. Lift the rear wiper blade retainer release tab until it is perpendicular to the wiper blade. 2. Lift the rear wiper arm off of the liftgate glass. 3. Position the rear wiper blade near the hook formation on the tip of the arm with the notched retainer for the wiper element oriented towards the end of the wiper arm that is nearest to the wiper motor output shaft. 4. Insert the hook formation on the tip of the wiper arm through the opening in the wiper blade superstructure ahead of the wiper blade pivot pin latch unit far enough to engage the pivot pin within the hook. 5. Slide the wiper blade pivot pin/latch up into the hook formation on the tip of the wiper arm. 6. Gently lower the wiper blade onto the liftgate glass. 7. Press down on the rear wiper blade retainer release tab until it snaps into its locked position over the top of the rear wiper arm. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Description and Operation Wiper Control Module: Description and Operation FRONT WIPER MODULE The wiper module is secured with screws through four rubber grommet-type insulators to the cowl plenum panel and concealed within the cowl plenum area beneath the cowl plenum cover/grille panel. The ends of the wiper pivot shafts that protrude through dedicated openings in the cowl plenum cover/grille panel to drive the wiper arms and blades are the only visible components of the wiper module. The wiper module consists of the following major components: Bracket - The wiper module bracket consists of a long tubular steel main member that has a stamped pivot bracket formation near each end where the two wiper pivots are secured. A stamped steel mounting plate for the wiper motor is secured with welds near the center of the main member. - Crank Arm - The wiper motor crank arm is a stamped steel unit that has a slotted hole on the driven end that is secured to the wiper motor output shaft with a nut, and has a ball stud secured to the drive end. - Linkage - The two wiper linkage members are each constructed of stamped steel. A driver side drive link with a plastic socket-type bushing in the left end, and a plastic sleeve-type bushing in the right end. Socket bushing is snap-fit over the pivot ball stud on the left pivot, while the sleeve bushing is fit over the longer wiper motor crank arm pivot stud. The passenger side drive link has a plastic socket-type bushing on each end. One end of this drive link is snap-fit over the pivot ball stud on the right pivot, while the other end is snap-fit over the exposed end of the longer ball stud on the wiper motor crank arm. - Motor - The wiper motor is secured with three screws to the motor mounting plate near the center of the wiper module bracket. The wiper motor output shaft passes through a hole in the module bracket, where a nut secures the wiper motor crank arm to the motor output shaft. The two-speed permanent magnet wiper motor features an integral transmission, an internal park switch, and an internal Positive Temperature Coefficient (PTC) circuit breaker. - Pivots - The two wiper pivots are secured to the ends of the wiper module bracket. The crank arms that extend from the bottom of the pivot shafts each have a ball stud on their end. The upper end of each pivot shaft where the wiper arms will be fastened each has an externally serrated drum secured to it. The wiper module cannot be adjusted or repaired. If any component of the module is faulty or damaged, the entire wiper module unit must be replaced. The wiper module operation is controlled by the vehicle operator through battery current inputs received by the wiper motor from the multi-function switch on the steering column. The wiper motor speed is controlled by current flow to either the low speed or the high speed set of brushes. The park switch is a single pole, single throw, momentary switch within the wiper motor that is mechanically actuated by the wiper motor transmission components. The park switch alternately closes the wiper park switch sense circuit to ground or to battery current, depending upon the position of the wipers on the glass. This feature allows the motor to complete its current wipe cycle after the wiper system has been turned OFF, and to park the wiper blades in the lowest portion of the wipe pattern. The automatic resetting circuit breaker protects the motor from overloads. The wiper motor crank arm, the two wiper linkage members, and the two wiper pivots mechanically convert the rotary output of the wiper motor to the back and forth wiping motion of the wiper arms and blades on the glass. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Description and Operation > Page 8056 Wiper Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the front wiper arms from the wiper pivots. (Refer to FRONT WIPER ARMS - REMOVAL). 3. Remove the cowl plenum cover/grille panel from the cowl plenum. Fig.11 Wiper Module Removal/Install 4. Remove the four screws that secure the front wiper module bracket to the cowl plenum panel and the dash panel. 5. Reach into the cowl plenum to move the front wiper module far enough to access the wiper module electrical connections. 6. Disconnect the headlamp and dash wire harness connector for the front wiper motor from the wiper motor pigtail wire connector. 7. Disconnect the headlamp and dash wire harness ground connector from the front wiper motor ground terminal. 8. Remove the front wiper module from the cowl plenum as a unit. INSTALLATION 1. Position the front wiper module into the cowl plenum as a unit. 2. Reconnect the headlamp and dash wire harness ground connector to the front wiper motor ground terminal. 3. Reconnect the headlamp and dash wire harness connector for the front wiper motor to the wiper motor pigtail wire connector. 4. Reach into the cowl plenum to align the front wiper module mounting bracket with the locations for the mounting screws. 5. Install and tighten the four screws that secure the front wiper module bracket to the cowl plenum panel and the dash panel. Tighten the screws to 8 Nm (72 in. lbs.). 6. Reinstall the cowl plenum cover/grille panel over the top of the cowl plenum. 7. Reinstall the front wiper arms onto the wiper pivots. (Refer to FRONT WIPER ARMS - INSTALLATION). 8. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams Wiper Motor: Diagrams Front Wiper Motor Rear Wiper Motor Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 8060 Wiper Motor: Description and Operation Fig. 12 Rear Wiper Motor REAR WIPER MOTOR The rear wiper motor is concealed within the liftgate, below the liftgate glass and behind the liftgate trim panel. The end of the motor output shaft that protrudes through the liftgate outer panel to drive the rear wiper arm and blade is the only visible component of the rear wiper motor. A rubber bezel and grommet is secured with a nut to the motor output shaft to seal and secure the unit to the liftgate outer panel, and a plastic nut cover snaps over the top of the bezel for a neat appearance. The rear wiper motor consists of the following major components: Bracket - The rear wiper motor bracket consists of a stamped steel mounting plate for the wiper motor that is secured with screws to the wiper motor housing, and through two rubber grommet-type insulators to the liftgate inner panel. - Motor - The single-speed permanent magnet rear wiper motor is secured with screws to the rear wiper module bracket. The wiper motor includes an integral transmission, a motor output shaft, an automatic re-setting circuit breaker, and the rear wiper motor park switch. The rear wiper motor cannot be adjusted or repaired. If any component of the motor is faulty or damaged, the entire rear wiper motor unit must be replaced. The motor output shaft bezel and grommet, nut, and nut cap are available for service replacement. The rear wiper motor operation is controlled by the rear wiper relay, which controls battery current flow to the rear wiper motor brushes based upon control outputs from the Central Timer Module (CTM). The CTM uses internal programming, hard wired outputs from the rear wiper motor park switch, and electronic messages received over the Programmable Communications Interface (PCI) data bus network from the rear wiper and washer switches in the air conditioner-heater control to determine when to energize or de-energize the rear wiper relay. The rear wiper motor park switch is a single pole, single throw, momentary switch within the wiper motor that is mechanically actuated by the wiper motor transmission components. The park switch alternately closes and opens a path to ground for the rear wiper motor control circuit input to the CTM, depending upon the position of the rear wiper blade on the liftgate glass. This feature allows the CTM to monitor the number of rear wiper motor cycles, as well as to keep the rear wiper relay energized long enough for the motor to complete its current wipe cycle after the wiper system or the ignition has been turned OFF, and to park the wiper blade in the lowest portion of the wipe pattern. The rear wiper motor is grounded at all times through a take out with an eyelet terminal connector in the body wire harness that is secured by a nut to a ground stud located on the lower left D-pillar in the passenger compartment. The automatic resetting circuit breaker protects the motor from overloads. The rear wiper motor transmission converts the rotary output of the wiper motor to the back and forth wiping motion of the rear wiper arm and blade on the liftgate glass. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 8061 Wiper Motor: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the rear wiper arm from the rear wiper motor output shaft. (Refer to REAR WIPERS/WASHERS/REAR WIPER ARM - REMOVAL). Fig. 13 Rear Wiper Motor Remove/Install 3. Use a door trim panel removal tool to gently pry at the base of the nut cover where it meets the wiper motor output shaft bezel and grommet on the outer liftgate panel until it unsnaps from the rear wiper motor output shaft bezel. Be certain to use proper caution to protect the outer liftgate panel and its paint finish from damage during this procedure. 4. From the outside of the liftgate, remove the nut that secures the rear wiper motor output shaft to the liftgate outer panel. 5. Remove the bezel and grommet from the rear wiper motor output shaft. 6. Remove the trim panel from the inside of the liftgate. 7. Disconnect the liftgate wire harness connector for the rear wiper motor from the motor pigtail wire connector. 8. Remove the two screws that secure the rear wiper motor mounting bracket to the liftgate inner panel. 9. Remove the rear wiper motor and mounting bracket from the liftgate as a unit. INSTALLATION 1. Position the rear wiper motor and mounting bracket into the liftgate as a unit. 2. Loosely install the two screws that secure the rear wiper motor mounting bracket to the liftgate inner panel. 3. From the outside of the liftgate, position the bezel and grommet over the motor output shaft. 4. Center the rear wiper motor output shaft in the liftgate outer panel mounting hole and secure it with the shaft retaining nut. Tighten the nut to 5 Nm (43 in. lbs.). 5. From the inside of the liftgate, tighten the two screws that secure the rear wiper motor mounting bracket to the liftgate inner panel. Tighten the screws to 8 Nm (72 in. lbs.). 6. Reconnect the liftgate wire harness connector for the rear wiper motor to the motor pigtail wire connector. 7. Reinstall the trim panel onto the inside of the liftgate. 8. From the outside of the liftgate, snap the nut cover onto the rear wiper motor output shaft bezel. 9. Reinstall the rear wiper arm onto the rear wiper motor output shaft (Refer to REAR WIPERS/WASHERS/REAR WIPER ARMS INSTALLATION). 10. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Power Distribution Center Wiper Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 8065 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 8066 Wiper Relay: Diagrams Front Wiper Motor Relay Rear Wiper Relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 8067 Wiper Relay: Description and Operation FRONT WIPER RELAY The front wiper relay (or intermittent wipe relay) is located in the Power Distribution Center (PDC) near the battery in the engine compartment. See the fuse and relay layout label affixed to the inside surface of the PDC cover for front wiper relay identification and location. The front wiper relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The relay is contained within a small, rectangular, molded plastic housing. The relay is connected to all of the required inputs and outputs through its PDC receptacle by five male spade-type terminals that extend from the bottom of the relay base. The ISO designation for each terminal is molded into the base adjacent to the terminal. The ISO terminal designations are as follows: 30 (Common Feed) - This terminal is connected to the movable contact point of the relay. - 85 (Coil Ground) - This terminal is connected to the ground feed side of the relay control coil. - 86 (Coil Battery) - This terminal is connected to the battery feed side of the relay control coil. - 87 (Normally Open) - This terminal is connected to the normally open fixed contact point of the relay. - 87A (Normally Closed) - This terminal is connected to the normally closed fixed contact point of the relay. The front wiper relay cannot be adjusted or repaired. If the relay is damaged or faulty, it must be replaced. The front wiper relay (or intermittent wipe relay) is an electromechanical switch that uses a low current input from the Central Timer Module ( CTM) to control a high current output to the low speed brush of the front wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor or diode is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The front wiper relay terminals are connected to the vehicle electrical system through a connector receptacle in the Power Distribution Center (PDC). The inputs and outputs of the front wiper relay include: The common feed terminal (30) is connected to the front wiper motor low speed brush through the wiper control circuitry of the multi-function switch on the steering column. When the front wiper relay is de-energized, the common feed terminal is connected to the front wiper park switch output through the CTM on the front wiper park switch sense circuit. The front wiper park switch output may be battery current (wipers are not parked), or ground (wipers are parked). When the front wiper relay is energized, the common feed terminal of the relay is connected to battery current from a fuse in the Junction Block (JB) through a fused ignition switch output (run-acc) circuit. - The coil ground terminal (85) is connected to the relay control output of the CTM through the wiper relay control circuit. The CTM controls the ground path for this circuit internally to energize or de-energize the front wiper relay based upon its programming, inputs from the front wiper and washer control circuitry of the multi-function switch, and inputs from the front wiper motor park switch. The coil battery terminal (86) is connected to battery current from a fuse in the Junction Block (JB) through a fused ignition switch output (run-acc) circuit whenever the ignition switch is in the ON or Accessory positions. - The normally open terminal (87) is connected to battery current from a fuse in the Junction Block (JB) through a fused ignition switch output (run-acc) circuit whenever the front wiper relay control coil is energized by the CTM. This circuit provides fused ignition switch output (run-acc) current to the front wiper motor low speed brush only when the front wiper relay control coil is energized. - The normally closed terminal (87A) is connected to the output of the front wiper motor park switch through the CTM on the front wiper park switch sense circuit. This circuit provides battery current (wipers are not parked) or ground (wipers are parked) to the front wiper motor low speed brush whenever the front wiper relay control coil is de-energized and the OFF position of the front wiper control circuitry within the multi-function switch is selected. The front wiper relay can be diagnosed using conventional diagnostic tools and methods. REAR WIPER RELAY The rear wiper relay is located in the Power Distribution Center (PDC) near the battery in the engine compartment. See the fuse and relay layout label affixed to the inside surface of the PDC cover for rear wiper relay identification and location. The rear wiper relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The relay is contained within a small, rectangular, molded plastic housing. The relay is connected to all of the required inputs and outputs through its PDC receptacle by five male spade-type terminals that extend from the bottom of the relay base. The ISO designation for each terminal is molded into the base adjacent to the terminal. The ISO terminal designations are as follows: 30 (Common Feed) - This terminal is connected to the movable contact point of the relay. - 85 (Coil Ground) - This terminal is connected to the ground feed side of the relay control coil. - 86 (Coil Battery) - This terminal is connected to the battery feed side of the relay control coil. - 87 (Normally Open) - This terminal is connected to the normally open fixed contact point of the relay. - 87A (Normally Closed) - This terminal is connected to the normally closed fixed contact point of the relay. The rear wiper relay cannot be adjusted or repaired. If the relay is damaged or faulty, it must be replaced. The rear wiper relay is an electromechanical switch that uses a low current input from the Central Timer Module (CTM) to control a high current output to the rear wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 8068 contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor or diode is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The rear wiper relay terminals are connected to the vehicle electrical system through a connector receptacle in the Power Distribution Center (PDC). The inputs and outputs of the rear wiper relay include: - The common feed terminal (30) is connected to the rear wiper motor through the rear wiper motor control circuit to the rear wiper motor. When the rear wiper relay is de-energized, the common feed terminal is connected to ground through a take out and eyelet terminal connector of the headlamp and dash wire harness that is secured by a nut to a ground stud located on the left front fender inner shield in the engine compartment near the battery. When the rear wiper relay is energized, the common feed terminal of the relay is connected to battery current from a fuse in the Power Distribution Center (PDC) through a fused B(+) circuit. - The coil ground terminal (85) is connected to the relay control output of the CTM through the rear wiper relay control circuit. The CTM controls the ground path for this circuit internally to energize or de-energize the rear wiper relay based upon its programming, electronic wiper and washer switch state message inputs from the heater-air conditioner control, and a hard wired input from the rear wiper motor park switch. - The coil battery terminal (86) is connected to battery current from a fuse in the PDC through a fused B(+) circuit at all times. - The normally open terminal (87) is connected to battery current from a fuse in the PDC through a fused B(+) circuit at all times. - The normally closed terminal (87A) is connected to ground through a take out and eyelet terminal connector of the headlamp and dash wire harness that is secured by a nut to a ground stud located on the left front fender inner shield in the engine compartment near the battery. The rear wiper relay can be diagnosed using conventional diagnostic tools and methods. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Front Wiper Relay Test Wiper Relay: Testing and Inspection Front Wiper Relay Test Fig. 9 Front Wiper Relay The front wiper relay (or intermittent wipe relay) is located in the Power Distribution Center (PDC) in the engine compartment. See the fuse and relay layout label affixed to the inside surface of the PDC cover for front wiper relay identification and location. 1. Remove the front wiper relay from the PDC. (Refer to FRONT WIPER RELAY - REMOVAL). 2. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 4. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, test the relay input and output circuits. Refer to RELAY CIRCUIT TEST . If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to the multi-function switch. There should be continuity between the receptacle for terminal 30 of the front wiper relay in the PDC and the intermittent front wiper low speed circuit cavity of the instrument panel wire harness connector for the multi-function switch at all times. If OK, go to Step 2. If not OK, repair the open intermittent front wiper low speed circuit between the PDC and the multi-function switch as required. 2. The relay normally closed terminal (87A) is connected to the front wiper motor park switch through the CTM on the front wiper park switch sense circuit. There should be continuity between the receptacle for terminal 87A of the front wiper relay in the PDC and the front wiper park switch sense circuit cavity of the headlamp and dash wire harness connector for the wiper motor at all times. If OK, go to Step 3. If not OK, repair the open front wiper park switch sense circuit between the PDC and the front wiper motor as required. 3. The relay normally open terminal (87) is connected to a fused ignition switch output (run-acc) fuse in the Junction Block (JB) through a fused ignition switch output (run-acc) circuit. There should be battery voltage at the receptacle for terminal 87 of the front wiper relay in the PDC whenever the ignition switch is in the ON or Accessory positions. If OK, go to Step 4. If not OK, repair the open fused ignition switch output (run-acc) circuit between the PDC and the JB as required. 4. The coil battery terminal (86) is connected to a fused ignition switch output (run-acc) fuse in the JB through a fused ignition switch output (run-acc) circuit. There should be battery voltage at the receptacle for terminal 86 of the front wiper relay in the PDC whenever the ignition switch is in the ON or Accessory positions. If OK, go to Step 5. If not OK, repair the open fused ignition switch output (run-acc) circuit between the PDC and the JB as required. 5. The coil ground terminal (85) is connected to the output of the Central Timer Module (CTM) through the wiper relay control circuit. There should be continuity between the receptacle for terminal 85 of the front wiper relay in the PDC and the wiper relay control circuit cavity of the instrument panel wire harness connector (Connector C3) for the CTM at all times. If not OK, repair the open wiper relay control circuit between the PDC and the CTM as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Front Wiper Relay Test > Page 8071 Wiper Relay: Testing and Inspection Rear Wiper Relay Test Fig. 14 Rear Wiper Relay The rear wiper relay is located in the Power Distribution Center (PDC) in the engine compartment. See the fuse and relay layout label affixed to the inside surface of the PDC cover for rear wiper relay identification and location. 1. Remove the rear wiper relay from the PDC. (Refer to REAR WIPER RELAY - REMOVAL). 2. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 4. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, test the relay input and output circuits. Refer to RELAY CIRCUIT TEST. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to the multi-function switch. There should be continuity between the receptacle for terminal 30 of the rear wiper relay in the PDC and the rear wiper motor control circuit cavity of the liftgate wire harness connector for the rear wiper motor at all times. If OK, go to Step 2. If not OK, repair the open rear wiper motor control circuit between the PDC and the rear wiper motor as required. 2. The relay normally closed terminal (87A) is connected to ground. There should be continuity between the receptacle for terminal 87A of the rear wiper relay in the PDC and a good ground at all times. If OK, go to Step 3. If not OK, repair the open ground circuit to ground (G113) as required. 3. The relay normally open terminal (87) is connected to a fused B(+) fuse in the PDC through a fused B(+) circuit. There should be battery voltage at the receptacle for terminal 87 of the rear wiper relay at all times. If OK, go to Step 4. If not OK, repair the open B(+) circuit between the PDC and the battery as required. 4. The coil battery terminal (86) is connected to a fused B(+) fuse in the PDC through a fused B(+) circuit. There should be battery voltage at the receptacle for terminal 86 of the rear wiper relay at all times. If OK, go to Step 5. If not OK, repair the open B(+) circuit between the PDC and the battery as required. 5. The coil ground terminal (85) is connected to the output of the Central Timer Module (CTM) through the rear wiper relay control circuit. There should be continuity between the receptacle for terminal 85 of the rear wiper relay in the PDC and the rear wiper relay control circuit cavity of the instrument panel wire harness connector (Connector C3) for the CTM at all times. If not OK, repair the open rear wiper relay control circuit between the PDC and the CTM as required. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Service and Repair > Front Wiper Relay Replacement Wiper Relay: Service and Repair Front Wiper Relay Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. Fig. 10 Power Distribution Center - Typical 2. Remove the cover from the Power Distribution Center (PDC). 3. See the fuse and relay layout label affixed to the underside of the PDC cover for front wiper relay identification and location. 4. Remove the front wiper relay by grasping it firmly and pulling it straight out from the receptacle in the PDC. INSTALLATION 1. See the fuse and relay layout label affixed to the underside of the PDC cover for the proper front wiper relay location. 2. Position the front wiper relay in the proper receptacle in the PDC. 3. Align the front wiper relay terminals with the terminal cavities in the PDC receptacle. 4. Push firmly and evenly on the top of the front wiper relay until the terminals are fully seated in the terminal cavities in the PDC receptacle. 5. Reinstall the cover onto the PDC. Dodge Durango 2wd Workshop Manual (V8-4.7L VIN N (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Service and Repair > Front Wiper Relay Replacement > Page 8074 Wiper Relay: Service and Repair Rear Wiper Relay Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. Fig. 15 Power Distribution Center - Typical 2. Remove the cover from the Power Distribution Center (PDC) . 3. See the fuse and relay layout label affixed to the underside of the PDC cover for rear wiper relay identification and location. 4. Remove the rear wiper relay by grasping it firmly and pulling it straight out from the receptacle in the PDC. Fig. 10 Rear Wiper Blade INSTALLATION 1. See the fuse and relay layout label affixed to the underside of the PDC cover for the proper rear wiper relay location. 2. Position the rear wiper relay in the proper receptacle in the PDC.